Skip to main content

Full text of "Yamaha Vmax Vmx12-Service-Manual"

See other formats


YAMAHA 



VMXI2N, 
NC~K, KC 



Service Manual 








YAMAHA 



'"• 



fc^v 



VMK12H 
VMX12HC 

SUPPLEMENTARY 
SERVICE MANUAL 






f 



LIT-11616-10-12 



FOREWORD 



This Supplementary Service Manual has been prepared to introduce new service and data 
for the VMX12H/VMX12HC. For complete service information procedures it is necessary to 
use this Supplementary Service Manual together with the following manual. 



VMX12N SERVICE MANUAL: 2WE-281 97-10 
VMXI2F SUPPLEMENTARY SERVICE MANUAL: 2WE-28197-11 






r* 



VMX12H/VMX12HC 

SUPPLEMENTARY 

SERVICE MANUAL 

01995 by Yamaha Motor Co. Ltd. 

1st Edition, July 1995 

All rights resewed. 

Any reprinting or unauthorized use 

without the written permission of 

Yamaha Motor Co., Ltd. 

is expressly prohibited. 



NOTICE 



This model has been designed and manufactured to perform within certain specifications 
in regard to performance and emissions. Proper service with the correct tools in neces- 
sary to ensure that the motorcycle will operate as designed. If there is any question about 
a service procedure, it is imperative that you contact a Yamaha dealer for any service 
information changes that apply to this model. This policy is intended to provide the cus- 
tomer with the most satisfaction from his motorcycle and to conform with federal envi- 
ronmental quality objectives. 



NOTE: 

For USA, California: 

This Service Manual contains information regarding periodic maintenance to the emission 
control system. Please read this material carefully. 



PARTICULARY IMPORTANT INFORMATION 

This material is distinguished by the following notation. 



A WARNING 



NOTE: 



The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
SAFETY B INVOLVED! 

Failure to follow WARNING instructions could result in severe injury or 
death to the motorcycle operator, a bystander, or a person inspecting 
or repairing the motorcycle. 

A CAUTION indicates special precautions that must be taken to avoid 
damage to the motorcycle. 

A NOTE provides key information to make procedures easier or clearer. 



HOWTO USETHIS MANUAL 

CONSTRUCTION OF THIS MANUAL 

This manual consists of chapters for the main categories of subjects. (See "Illustrated sym- 
bols") 



Isttitle©: 

2nd title©: 

3rd title (3): 



This is a chapter with its symbol on the upper right of each page. 

This title appears on the upper of each page on the left of the chapter 
symbol. (Forthe chapter "Periodic inspection and adjustment" the 3rd 
title appears.) 

This is a final title. 



MANUAL FORMAT 

All of the procedures in this manual are organized in a sequential, step-by-step format. The 
information has been compiled to provide the mechanic with an easy to read, handy refer- 
ence that contains comprehensive explanations of all disassembly, repair, assembly, and 
inspections. 

A set of particularly important procedure (4) is placed between a line of asterisks "#"with 
each procedure preceded by "•". 

IMPORTANT FEATURES 

• Data and a special tool are framed in a box preceded by a relevant symbol d). 

• An encircled numeral© indicates a part name, and an encircled alphabetical letter data or 
an alignment mark®, the others being indicated by an alphabetical letter in a box(D. 

• A condition of a faulty component will precede an arrow symbol and the course of action 
required®. 

EXPLODED DIAGRAM 

Each chapter provides exploded diagrams before each disassembly section for ease in identi- 
fying correct disassembly and assembly procedures. 




© 








© 








GEN 
INFO 


#^ 


SPEC 


0- 


® 


© 


INSP 
ADJ 


<& 


ENG 


V» 


© 


© 


COOL 


* 


CARB 


9 


© 


© 


CHAS 


<§^ 


ELEC 


p *] 


© 


® 


*Q 




TRBL 
SHTG 


? 




© 


— 




© 


y. 




® 


X 




% 


^ 




© 


c 


^ 




8 


6 


11 





@ 



i 



# 



A 



© 



i 



© 



@ 



© 



© 



A 



New 



EB003000 

ILLUSTRATEDSYMBOLS 

Illustrated symbols to <§) are printed on 
top right of each page and indicate the sub- 
ject of each chapter. 

© General information 

© Specifications 

© Periodic inspections and adjustments 

© Engine 

© Cooling system 

© Carburetion 

(7) Chassis 

© Electrical 

© Troubleshooting 



Illustrated symbols ® to @ are used to 
identify the specifications appearing in the 
text. 

© Filling fluid 

© Lubricant 

© Special tool 

©Torque 

@Wear limit, clearance 

© Engine speed 

% Q., V, A 



Illustrated symbols© to © in the exploded 
diagrams indicate the types of lubricants 
and lubrication points. 

©Apply engine oil 

® Apply gear oil 

©Apply molybdenum disulfide oil 

©Apply wheel bearing grease 

©Apply lightweight lithium-soap base grease 

©Apply molybdenum disulfide grease 

Illustrated symbols <g^> to @ in the exploded 

diagrams indicate the where to apply locking 

agent© and when to install new parts®. 

©Apply locking agent (LOCTITE®) 
© Replace 



,- 



CONTENTS 



GENERAL INFORMATION 

MOTORCYCLE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

FRAME SERIAL NUMBER 

ENGINE SERIAL NUMBER 

SPECIAL TOOLS 



SPECIFICATIONS 3 

GENERAL SPECIFICATIONS 3 

MAINTENANCE SPECIFICATIONS 3 

ENGINE 3 

ELECTRICAL 4 

PERIODIC INSPECTION AND ADJUSTMENT 5 

ENGINE 5 

ENGINE OIL REPLACEMENT 5 

ENGINE OVERHAUL 7 

INSPECTION AND REPAIR 7 

CRANKSHAFT AND CONNECTING ROD 7 

BALANCER SHAFT 1 1 

MIDDLE GEAR SERVICE 1 3 

CHASSIS 14 

SHAFT DRIVE 14 



MOTORCYCLE IDENTIFICATION 



GEN 
INFO 



$N^ 




GENERAL INFORMATION 

MOTORCYCLE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number (?) is 
stamped into the right side of the steering 
pipe. 



Starting serial number: 
JYA2WEE0 -X-TA050101 (USA) 
JYA2WFC0-KTA012101 (California) 



NOTE: 

The vehicle identification number is used to 
identify your motorcycle and may be used 
to register your motorcycle with the licens- 
ing authority in your state. 



^^2^>-v3^ 




>^4V^/ 






yTJV™i 


~---=^^sF\ \ 


% 




Z M 




'^'^Zj^TK \ 




FRAME SERIAL NUMBER 

The frame serial number© is stamped into 
the right side of the steering pipe. 



Starting serial number: 
2EN-042101 (EUR) 



NOTE: 

The first three digits of these numbers are 
for model identifications; the remaining 
digits are the unit production number. 

ENGINE SERIAL NUMBER 

The engine serial number (?) is stamped 
into the crankcase. 

Starting serial number: 
2WE-050101 (USA) 
2WF-012101 (California) 
2EN-042101 (EUR) 

NOTE: 

• The first three digits of these numbers are 
for model identification; the remaining 
digits are the unit production number. 

• Designs and specifications are subject to 
changewithout notice. 




SPECIAL TOOLS 



SIB <^ 



SPECIAL TOOLS 

The proper special tools are necessary for 
complete and accurate tune-up and assem- 
bly. Using the correct special tool will help 
prevent damage caused by the use of 
improper tools or improvised techniques. 
The shape and part number used for the 
special tool differ by country, so two types 
are provided. 



Refer to the list provided to avoid errors 
when placing an order. 



P/N.YM- DDDDD, YU-DDDDD 

ys- ddddd,yk-ddddd 

ACC-DDDDD 
P/N. 90890- DDDDD 



For 
US, CON 



Exceptfor 
US,CDN 



FOR ENGINE SERVICE 



Oil filter wrench 

YU-38411 

P/N. 90890-01426 












V 




\ 




iThis tool is used to 
Ifilter. 


remove 


and 


install the 


oil 



GENERAL SPECIFICATIONS/ 
MAINTENANCE SPECIFICATIONS 



SPEC 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



Model 


VMX12 


Model code: 


3JPM (USA) 
3JPN (California) 
3LRA (EUR) 


Engine starting number: 


2WE-050101 (USA) 
2WF-012101 (California) 
2EN-042101 (EUR) 


Vehicle identification number: 


JYA2WEE0*TA050101 (USA) 
JYA2WFC0*TA012101 (California) 


Frame starting number: 


2EN-042101 (EUR) 


Basicweight: 
With oil and full fuel tank 


283 kg (624 lb) (USA) 

284 kg (626 lb) (California) 
281 kg (620 lb) (EUR) 



MAINTENANCE SPECIFICATIONS 

ENGINE 



Model 


VMX12 


Carburetor: 






I.D.Mark 




1FK02 (USA), 2WF 02 (California), 3LR 01 (EUR) 


Mainjet 


(M.J) 


#152.5 (USA, California), #150 (EUR) 


Main airjet 


(M.AJ) 


82.0 


Jet needle 


(J.N) 


5EZ43-1 (USA), 5EZ50-1 (California), 
5EZ19-3(EUR) 


Needlejet 


(N.J) 


Y-0 


Pilot jet 


(P.J) 


#37.5 (USA, California), #42.5 (EUR) 


Pilotair jet 


(P.A.J. 1) 


#90 (USA),#1 OO(Califomia), #95 (EUR) 


Pilot screw 


(PS) 


2-1/4 (USA), 3 (California), 2-1/2 (EUR) 


Pilot outlet 


(P.O) 


0.9 


Bypass 1 


(B.P.I) 


0.8 


Bypass 2 


(B.P.2) 


0.8 


Bypass 3 


(B.P.3) 


0.9 


Valve seat size 


(V.S) 


1.5 


Starterjet 


(G.S.1) 


#45 


Starterjet 


(G.S.2) 


#0.8 


Throttle valve size 


(Th.V) 


#125 (USA, EUR), #130 (California) 


Fuel level 


(F.L) 


15 -17 mm (0.59-0.66 in) 


Engine idling speed 




950 -1,050 r/min (USA, EUR), 
1,050- 1,150 r/min (California) 


Vacuum pressure at idling 


speed 


26.7 kPa(200mmHg, 7.87 in Hg)(USA, EUR) 
33.3 kPa (250 mmHg, 9.84 in Hg) (California) 



MAINTENANCE SPECIFICATIONS |SPEC| t^" I 



ELECTRICAL 



Model 


VMX12 


Rectifier: 
Model/ manufacturer 
Capacity 
Withstand Voltage 


SH662-12/SHINDENGEN 
25 A 
200 V 


Electric starter system: 

TYPe 

Starter motor: 

Model/ manufacturer 

output 

Brush overall length 

<Limit> 

Commutator diameter 

<Wear limit> 

Mica undercut 
Starter switch: 

Model/ manufacturer 

Amperage rating 

Coil winding resistance 


Constant mesh type 

SM-13/ MITSUBA 
0.65 kW 

12.5 mm (0.49 in) 
<5.0 mm (0.20 in) 
28 mm(1.10in) 
<27 mm (1.06 in)> 
0.7 mm (0.03 in) 

MS5D-1 91/ HITACHI 

100A 

3.9- 4.7Qat20°C(68°F) 


Thermostatic switch: 
Model/ manufacturer 


2EL (USA),47X (California, EUR)/ 
NIHON THERMOSTAT 



-4- 



ENGINE OIL REPLACEMENT 



INSP 
ADJ 



o 



PERIODIC INSPECTION AND 
ADJUSTMENT 

ENGINE 

ENGINE OIL REPLACEMENT 

1. Start the engine and let it warm up for 

several minutes. 
2. Stop the engine and place an oil pan 

underthe drain bolt. 




3. Remove: 

• Oilfiller cap© 



4. Remove: 

• Drain bolt (T) (with gasket) 

Drain the crankcase of its oil. 
5. If the oil filter is to be replaced during this 

oil change, remove the following parts 

and reinstall them. 



********************************** 

Replacement steps: 

• Remove the oil filter (T) using the oil filter 
wrench (5). 



m 



Oil filter wrench: 
YU-3841 1,90890-01 426 



• Apply engine oil to the O-ring (3) of the 
new oil filter. 

NOTE: 

Make sure the O-ring (3) is positioned cor- 
rectly. 

• Tighten the oil filter using the oil filter 
wrench. 




Oil filter: 
18 Nm (1.8 m. kg, 13ft' lb) 



********************************** 



•5- 



ENGINE OIL REPLACEMENT 



I NSP 
ADJ 



<& 




Drain bolt: 
43Nm(4.3m-kg,31ft» lb) 



NOTE: 

Always use a new gasket. 



3 





4 


5 





60" F 




















" [A. 

















5 1 





15°C 



7. Fill: 

• Crankcase 



<\ 


Recommended oil: 


At5°C(40°F)orhigheriA: 




SAE20W40typeSEmotoroil 






At 15°C(60°F)or lower [§]: 




SAE 10W30type SE motor oil 




Oil quantity: 




Total amount: 




4.7 1,(4.1 Impqt, 5.0 US qt) 




Periodic oil change: 




3.5 L(3.1 Impqt, 3.7 US qt) 




With oil filter replacement: 




3.8 L (3.3 Impqt, 4.0 US qt) 



NOTE: 

Recommended oil classification: API Ser- 
vice "SE", "SF" and "SG" type or equiva- 
lent (e.g. "SF-SE" , "SF-SE-CC" , "SF-SE- 
SD" etc.). 



"> 



"~^ 



• Do not add any chemical additives. 
Engine oil also lubricates the clutch and 
additives could cause clutch slippage. 

• Do not allowforeign materialto enterthe 
crankcase. 



ainstall: 

• Oil filler cap 

9. Warm up the engine for a few minutes, 

then stop the engine. 
10. Inspect: 

• Engine (for oil leaks) 

• Oil level 



■6- 



INSPECTIONAND REPAIR 



ENG 



% 




ENGINE OVERHAUL 

INSPECTIONAND REPAIR 
CRANKSHAFT AND CONNECTING ROD 

1. Measure: 

• Runout (crankshaft) 
Out of specification -> Replace. 




Runout: 
Less than 0.03 mm (0.0012 in) 



2.1 nspect: 

• Main journal surfaces 

• Crank pin surfaces 

• Bearing surfaces 
Wear/Scratches —> Replace. 



3. Measure: 

• Oil clearance (mainjournal) 



Out of specification — > Replace bearing. 



Oil clearance: 
0.020 ~ 0.038 m m 
(0.0008 -0.0015 in) 




********************************** 



Measurement steps: 



CMJTiON: 



Do not interchange the bearings and con- 
necting rod. They must be installed in their 
original positions, or the correct oil clear- 
ance may not be obtained causing engine 
damage. 

• Clean the bearings, main journals and 
bearing portions of the crankcase. 

• Place the crankcase (upper) on a bench in 
an upside down position. 

• Install the upper half of the bearings and 
the crankshaft into the crankcase (upper). 

NOTE: 

Align the projection of the bearing with the 
notch in the crankcase. 



USPECTDN AND REPAH 



ENG 



• Putl a piece of Piastgauge® 

pumaL 

NOTE: 



on each m a±i 



Do not put the Pkstgauge® over the oiL 
hole ii the m ail journal of the crankshaft, 

• install the lowerhalf of the bearings iito 
the crankcase (bwer) and assemble the 
crankcase halves. 




NOTE: 

■ Align the pro^pction of the bearhg wih 
the notch ii the crankcase . 

• Do not m ove the crankshaft until the oiL 
clearance has been completed. 

• Tighten the bols to specification in the 
tightening sequence cast on the crank- 
case . 




Bolt (Crankcase -M10): 

40 Nm (4.0 m*kg, 29 ft»: 



• W ith a washer 

•Remove the crankcase (lower) and lower 
half of the bearhg. 

• Measure the compressed Piistgauge® ' 
w iith (§J on each m ain journal 

If oiL clearance is out of specification , 
select a repbcem ent bearhg . 

4 M easure : 

• O itclearance (crank pii) 

O ut of specification — ) Repb.ce bearing. 



& 



Oil clearance: 
0.021 - 0.039 mm 

(0.0008 * 0.0015 in) 



M easurem ent steps : 



^ 



Do not interchange the bearings and con- 
necting rod. They must be installed in their 
original positions , or the correct oil clear- 
ance may not be obtained causing engine 
dam age . 



INSPECTIONAND REPAIR 



ENG 



\m 




• Clean the bearings, crank pins and bear- 
ing portions of the connecting rods. 

• Install the upper half of the bearing into 
the connecting rod and lower half of the 
bearing into the connecting rod cap. 

NOTE: 

Align the projection of the bearing with the 
notch of the cap and connecting rod. 

• Put a piece of Plastigauge® on the crank 
pin. 

• Assemble the connecting rod halves. 

NOTE: 

• Do not move the connecting rod or crank- 
shaft until the oil clearance measurement 
has been completed. 

• Apply molybdenum disulfide grease to 
the bolts, threads and nut seats. 

• Make sure the "Y" marks on the connect- 
ing rods face the left side of the crank- 
shaft. 

• Make sure that the letters on both compo- 
nents align to from a perfect character. 

• Tighten the nuts. 




Nut: 

36 Nm (3.6 m 



kg, 25 ft. lb) 



Tighten to full torque specificationwithout 
pausing. Apply continuous torque between 
3.0 and 3.8 nvkg. Once you reach 3.0 nvkg, 
DO NOT STOP TIGHTENING until final 
torque is reached. If tightening is inter- 
rupted between 3.0 and 3.8 nvkg, loosen 
nut to less than 3.0 nvkg and start again. 




• Remove the connecting rods and bear- 
ings. 

• Measure the compressed Plastigauge® 
width (a) on each crank pin. 

If oil clearance is out of specification, 
select a replacementbearing. 
********************************** 



USPECTDN AND REPAID 




ENG \« 



P1 P 2 



J1J2J3J4 





J1J2J3J4 




5.Select: 

* M ail JDumal bearing {JJ ■* J,) 
ms* C rank pii bearing (P, ~ P ,) 



Selection of bearings: 
Example 1: Mail journal bearing 
#|f| "J," on the crankcase is "6" and "1" on 
the crankweb, then the bearing size for 

'Jilt: 



Bearing size of J,: 
Crankcase J, - Crankweb J, = 
6-1=5 (Yellow) 


BEARING COLOR CODE 


1 


Blue 


2 


Black 


3 


Brown 


4 


Green 


5 


Yellow 


6 


Pink 


7 


Red 



Example 2: Crank pin bearing 

• If "Pi"| on the connecting rod is ^4" and 

"2" on the crankweb, then the bearing 

size for"P,"| is: 



Bearing size of P,: 
Connecting rod P, - Crankweb P, = 
4 -2 = 2 (Black) 


BEARING COLOR CODE 


1 


Blue 


2 


Black 


3 


Brown 


4 


Green 


5 


Yetlow 


6 


Pink 



^ 



> 



10- 



•***#****#*#***##**»**tt**«*»***#**l 



INSPECTIONAND REPAIR 



ENG 



% 



BALANCER SHAFT 

1. Measure: 

• Oil clearance (balancer shaft bearing) 
Out of specification -» Replace bearing. 




Oil clearance: 
0.020-0.048 mm 
(0.0008- 0.002 in) 



********************************** 

Measurement steps: 

• Clean the bearings, balancer shaft and 
bearing portions of the crankcase. 

• Place the crankcase (upper)on a bench in 
an upside down position. 

• Install the upper half of the bearings and 
the balancer shaft into the crankcase 
(upper). 

• Put a piece of Plastigauge® on each bal- 
ancer shaft journal. 

• Install the lower half of the bearings into 
the crankcase (lower) and assemble the 
crankcase halves. 



NOTE: 












Do not move the 


balancer shaft 


until the oil 


clearance 


measurement 


has 


been 


com- 


pleted. 














• Tighten the bolts to specification in the 
tightening sequence cast on the crank- 
case. 




Bolt (crankcase-M8): 
24Nm(2.4nvkg, 17ft«lb) 



• Remove the crankcase (lower) and lower 
half of the bearings. 

• Measure the compressed Plastigauge® 
width (|) on each balancer shaft journal. If 
oil clearance is out of specification, select 
a replacement bearing. 

********************************** 



-11- 



INSPECTION AND REPAIR 



eng|\. 



o 




[U] 


J5 J6 

u 

J2 \\ „ 

J 












2. Select: 

• Balancer shaft bearing 




********************************** 

Selection of bearings: 
Example: 

• If "J 6 " on the crankcase is "6" and "2" on 

the balancer shaft, then the bearing size 

for "J," is: 



Bearing size of J 6 : 
Crankcase J 5 - Balancer shaft No. □ 
6 ~2 □ 4 (Green) 




BEARING COLOR CODE 


1 


Blue 


2 


Black 


3 


Brown 


4 


Green 


5 


Yellow 


6 


Pink 


7 


Red 



********************************** 



-> • 



~> 



12- 



MIDDLE GEAR SERVICE 



ENG 


\m 



MIDDLE GEAR SERVICE 

© Universaljoint 

(D Dust seal 

(3) Housing 

© O-ring 

d) Bearing 

(6) Collapsible collar 

© Bearing 

(D Middle drive shaft 

(D Middle driven pinion gear 

(J§) Spring seat 



© Damper spring 

(g> Damper cam 

@ Middle drive pinion gear 

@Thrust washer 

© Retainer 



95 Nm {9,5 m*kg, 69 ft-ib) 



30 Nm (3.0m-kg, 22 fr lb) 








GEAR LASH: 
0.05 -0.12 mm 

(0.002 -0.005 in) 



SHIMS: 

0.15 mm (0.006 in) 

0.30 mm {0.012 in) 
0.50 mm (0.020 in) 



IIONm (ll.Om-kg, 80 ff lb) 
STAKE 



13- 



SHAFT DRIVE |CHAS (&%$\ 





CHASSIS 




SHAFT DRIVE 






(D Dust cover 


@ Bearing 


27Washer 


(2) Bearing housing 


@; Bearing 


@ Circlip 


(I) Ring gear stopper shim 


® Drive pinion gear 


© Bearing 


® Ring gear stopper 


@ Final drive gearshim 


@ Circlip 


©O-ring 


© Bearing 


® Universal joint 


® Oil seal 


® Bearing retainer 




(?) Ring gearshim 


@ O-ring 




Bearing 


©Oil seal 




® Ring gear 


©Coupling gear 




® Thrust washer 


@ Spring 




(f£ Bearing 


@: Circlip 




@ Oil seal 


@ Drive shaft 




©Collar 


@Oil seal 





^ 



~> 



A FINAL GEAR OIL: 



23 Nm (2.3m-kg, 17fflb) 



23 Nm (2.3 irvkg, 17 ft*lb) 



E SIZES: 2 



9Nm (0.9 m -kg. 6.5ft-lb) 




SIZES: 4 



CAPACITY: 

0.2 L<0.18 Imp qt, 0.21 USqt) 



TYPE: 

SAE 80 API GL4 HYPOIO GEAR OIL 



GEAR LASH: 

0.1 - 0.2 mm (0.004 - 0.008 in) 



23 Nm 

(2.3 m-kg, 17 ft- lb) 



110 Nm (11.0m- kg, 80 ft- lb) 



•V*$"* 



SIZES: 3 



130 Nm 

(13.0 m-kg, 94 ft-lb) 






23 Nm (2.3 m-kg, 17 fflb> 






*> 




42 Nm (4.2 m-kg, 30 ff lb) 



14- 



^ 



VAMAHA MOTOR CO.,l_TD. 



PRINTED ]N U.S.A. 



YAMAHA 



j~ 



VNIX12E 
VMX12EC 

SUF PLEMEHTARY 
SERVICE MANUAL 



r 



LIT-11 616-08-77 



FOREWORD 



This Supplementary Service Manual has been prepared to introduce new service and data for 
the VMX12E/VMX12EC. Forcomplete service information procedures it is necessary to use this 
Supplementary Service Manual together with the following manual. 



% 



VMX12N/VMX12NC SERVICE MANUAL: LIT-1 161 6-04-67 






VMX12S/VMX12SC SUPPLEMENTARY SERVICE MANUAL: 


LIT-11 616-04-98 


VMX12U/VMX12UC SUPPLEMENTARY SERVICE MANUAL 


LIT- 


11616-06-08 



VMXI2E/VMXI2EC 

SUPPLEMENTARY 

SERVICE MANUAL 

© 1992 by Yamaha Motor Co., Ltd. 

1st Edition, November 1992 

All rights reserved. 

Any reprinting or unauthorized use 

without the written permission of 

Yamaha Motor Co., Ltd. 

is expressly prohibited. 



NOTICE 

This manual was written by Yamaha MotorCompany Ltd. primarilyfor use by Yamaha dealers 
and qualified mechanics. It is not possible to put an entire mechanic's education into one 
manual, so persons using this book to perform maintenance and repairs on Yamaha motor- 
cycles should have a basic understanding of the mechanical concepts and procedures inherent 
in motorcycle repair technology. Without such knowledge, attempted repairs or service to the 
motorcycle may render it unfit to use and/or unsafe. 

This model has been designed and manufactured to perform within certain specifications in 
regard to performance and emissions. Proper service with the correct tools in necessary to 
ensure that the motorcycle will operate as designed. If there is any question about a service 
procedure, it is imperative that you contact a Yamaha dealer for any service information 
changes that apply to this model, This policy is intended to provide the customer with the most 
satisfaction from his motorcycle and to conform with federal environmental quality objectives. 
Yamaha Motor Company Ltd. is continually striving to improve all models manufactured by 
Yamaha. Modifications and significant changes in specifications or procedures will be for- 
warded to all Authorized Yamaha dealers and will, where applicable, appear in future editions 
of this manual. 



NOTE:. 



This Service Manual contains information regarding periodic maintenance to the emission 
control system. Please read this material carefully. 



PARTICULARLY IMPORTANT INFORMATION 

This material is distinguished by the following notation. 



A 



The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
SAFETY IS INVOLVED! 



A WARNING 



CAUTION: 



Failure to follow WARNING instructions could result in severe injury or 
death to the motorcycle operator, a bystander, or a person inspecting 
or repairing the motorcycle. 

A CAUTION indicates special precautions that must be taken to avoid 
damage to the motorcycle. 



NOTE: 



A NOTE provides key information to make procedures easier or clearer. 



HOW TO USE THIS MANUAL 

CONSTRUCTION OF THIS MANUAL 

This manual consists of chapters for the main categories of subjects. (See "Illustrated 

symbols") 

1 st title (T) : This is a chapter with its symbol on the upper right of each page. 

2nd title (2) : Thistitle appearsonthe upperof each page on the left ofthe chaptersymbol. 

(Forthe chapter "Periodic inspection and adjustment" the 3rd title appears.) 

3rd title (3): This is a final title. 



MANUAL FORMAT 

All of the procedures in this manual are organized Tn a sequential, step-by-step format. The 
information has been compiled to provide the mechanicwith an easy to read, handy reference 
thatcontainscomprehensiveexplanationsofalldisassembly, repair, assembly, and inspections. 



A set of particularly important procedure© is placed between a line of asterisks ' 
procedure preceded by " • ". 



with each 



IMPORTANT FEATURES 

• Data and a special tool are framed in a box preceded by a relevant symbol ©. 

• An encircled numeral ©indicates a part name, and an encircled alphabetical letterdata or an 
alignment mark (7), the others being indicated by an alphabetical letter in a box®. 

• A condition of a faulty component will precede an arrow symbol and the course of action 
required the symbol (§). 

EXPLODED DIAGRAM 

Each chapter provides exploded diagrams before each disassembly section for ease in 

identifying correct disassembly and assembly procedures. 



wsrccTK>hftNDftt»jUR E^G | \^ 




/tiffin J 



W*Iplf» |h*4-lUM«*MI *A* 



■fcliKh i»iriH|rti«tfoa i and •!".>-, 
**•• tuf # 1*W WMfttt* 

+imt* K00 — 400 vrt vol i*id>»Miie 
Ihi h»lM* ihli •ndfaiu'tMiih^Nkti 



«•■■■**■ IMIUhAllll^llH ■*» IMt 



FRONT FORK CHAS ^fofe 




X^J r.„niF.,.i,n, 



^ 



~> 







D 


© 


ILLUSTRATED SYMBOLS 
(Refertothe illustration) 

Illustrated symbols (j) to (g) are designed as 


GEN 
INFO 


#^ 


SPEC 


Pf 




® 


thumb tabs to indicate the chapter's number 
and content. 


D 


INSP 
ADJ 


Ka 


ENG 


\m 


(T) General information 

(2) Specifications 

(3) Periodic inspection and adjustment 






(4) Engine 


D 


CD 


(5) Cooling system 
(D Carburetion 


COOL 


x 


CARB 


* 


(7) Chassis 

(D Electrical 

(9) Troubleshooting 




© 


T> 




CHAS 


<£?$) 


|elec|H 










D 








Illustrated symbols ©to ©are used to iden- 




I® 




tify the specifications appearing in the text. 


TRBL 
SHTG 


• 


© Filling fluid 
© Lubricant 
©Specialtool 










0) 








©Tightening 


^ 




© 


f- 




©Wear limit, clearance 
© Engine speed 

©n,v,A 












Q) 






® 








\ 




% 


































^ 


a 




© 






















© @ © 

Q Q Q 


Illustrated symbols © to © in the exploded 
diagram indicategrade of lubricant and loca- 
tion of lubrication point. 

©Apply engine oil 

@ Apply gear oil 


© © @ 


©Apply molybdenum disufide oil 
©Apply wheel bearing grease 
©Apply lightweight lithium-soap base grease 
©Apply molybdenum disulfide grease 
©Apply locking agent (LOCTITE®) 


© 

i 


© 




© Use new one 


I New 1 

















CONTENTS 

GENERAL INFORMATION 1 

MOTORCYCLE IDENTIFICATION 1 

VEHICLE IDENTIFICATION NUMBER 1 

ENGINE SERIAL NUMBER 1 

SPECIAL TOOL 2 

FOR CHASSIS SERVICE 2 

SPECIFICATIONS 3 

GENERAL SPECIFICATIONS 3 

MAINTENANCE SPECIFICATIONS 4 

ENGINE 4 

CHASSIS 4 

ELECTRICAL 5 

CHASSIS 6 

FRONT AND REAR BRAKE 6 

FRONT FORK 7 

REMOVAL 8 

DISASSEMBLY 9 

INSPECTION 10 

ASSEMBLY 11 

INSTALLATION 14 

ELECTRICAL 16 

CIRCUIT DIAGRAM 16 

IGNITION SYSTEM 1 8 

DIGITAL IGNITION CONTROL SYSTEM DESCRIPTION 18 

OPERATION 18 

WIRING DIAGRAM 



MOTORCYCLE IDENTIFICATION 



GEN 
INFO 


#^ 




GENERAL 
INFORMATION 
MOTORCYCLE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER - 

The vehicle identification number (T) is 
stamped intnthp stpprinfl hpaH pips 



Starting serial number: 
VMX-Stert'.na s?TNl2WPfe§''* PA035101 

VMX1liG W «::::d¥AiWP§& * PAOdSIM 

\/MYi?Pr ivA?WF?<n*PAnninm 



NOTE: 

The vehicle identification number is used to 
identify your motorcycle and may be used to 
register your motorcycle with the licensing 
authority in your state. 




ENGINE SERIAL NUMBER 

The engine serial number© is stamped into 
the leftside of the engine. 

Starting serial number: 

YMX12E „ 2WE-035101 

VMX12EC 2WF-008101 

NOTE: 

• The first three digits of these numbers are 
for model identifications; the remaining 
digits are the unit production number. 

• Designs and specifications are subject to 
change without notice. 




SPECIAL TOOLS 



GEN 
INFO 


$N§ 



SPECIAL TOOLS 

The proper special tools are necessaryfor 
complete and accurate tune-up and assem- 
bly. Using the correct special tool will help 
prevent damage caused by the use of im- 
proper tools or improvised techniques. 
The shape and part number used for the 
special tool differ by country, so two types 
are provided. 



FOR CHASSIS SERVICE 



Referto the list providedto avoid errors when 

placing an order. 

P/N. YM- DDDDD, YU-DDDDD ForUSA, 
YS- DDDDD ,YK- DDDDD California, 
ACC-DDDDD CDN 



P/N.90890-DDDDD 



For EUR, 
AUS 



HI 

T-Handle© 
P/N.YM-01326 
P/N. 90890-01326 

For damper rod 
holder (29 mm) (?) 
P/N. YM-33962 
P/N. 90890-01375 

These tools are used to loosen and tighten the 
front fork damper rod holding bolt. 







Front fork seal driver 
(weight)® 
P/N. YM-33963 
P/N. 90890-01367 
Adapter (43 mm) (2) 
P/N. YM-8020 




GENERAL SPECIFICATIONS 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



Model 


VMX12E 


VMX12EC 


Model code number: 
Engine starting number: 
Vehicle identification number: 


3 J PC 

2WE-035101 

JYA2WEE0#PA035101 


3JPD 

2WF-008101 

JYA2WFCO*PA008101 


Minimum turning radius: 


2.900 mm (114 in) 


Carburetor: 
Type/Manufacturer 


BDS35x4/MIKUNI 


Tire: 

Type 
Size (F) 

Size (R) 

Wear limit 


Tubeless 

110/90V 18 

BRIDGESTONE G525AW/DUNLOP F20 

150/90V15 

BRIDGESTONE G526BW/DUNLOP K525 

1.0 mm (0.04 in) 


Tire pressure (cold tire): 
Basicweight: 
With oil and full fuel tank 

Maximum load* 

Cold tire pressure: 

Upto 90 kg (1981b) load* 

90 kg (198lb)*~ Maximum load* 


283 kg (624 lb) 
216 kg (476 lb) 


284 kg (626 lb) 
215 kg (474 lb) 


Front 


Rear 


225 kPa 
(2.25 kg/cm 2 , 32 psi) 


225 kPa 
(2.25 kg/cm 2 , 32 psi) 


225 kPa 
(2.25 kg/cm 2 , 32 psi) 


250 kPa 
(2.5 kg/cm 2 , 36 psi) 


* Load is the total weight of cargo, rider, 
passenger and accessories. 


Electrical: 
Ignition system 
Generator system 
Battery type or model 
Battery capacity 


T.C.I, (digital) 

A.C. magneto generator 

YB16AL-A2 

12V16AH 



-3- 



MAINTENANCE SPECIFICATIONS 



SPEC ff 



MAINTENANCE SPECIFICATIONS 

ENGINE 



Model 


VMX12E 


VMX12EC 


Carburetor: 








I.D. Mark 




1FK01 


2WE01 


Mainjet 


(M.J.) 


#152.5 


<- 


Main air jet 


(MA J.) 


02.0 


«- 


Jet needle 


(J.N.) 


5EZ43 


5EZ50 


Needlejet 


(N.J.) 


Y-0 


<- 


Pilotjet 


(P.J.) 


#37.5 


<- 


Pilot air jet 


(P.A.J.1) 


#90 


#100 


Pilot screw 


(P.S.) 


Preset 


<- 


Pilot outlet 


(P.O.) 


0.9 


«- 


Bypass 


(B.P.I) 


0.8 


<- 




(B.P.2) 


0.8 


<r- 




(B.P.3) 


0.9 


<- 


Valve seat size 


(VS.) 


1.5 


<r- 


Starterjet 


(G.S.1) 


#45 


<- 




(G.S.2) 


#0.8 


<r- 


Fuel level 




15-17 mm (0.59-O.66 in) 


<r- 


Engine idling speed 




950-1050 r/min 


1050-1150 r/min 


Vacuum pressure at idling 


speed 


200mmHg(7.87inHg) 


250mmHg(9.84inHg) 



CHASSIS 



I Model 


VMX12E/EC 


Front suspension: 






Frontfork travel 


140mm (5.51 in) 




Fork spring free length 


386.5 mm (15.2 in) 




<Limit> 


381.5 mm (15.0 in) 




Collar length 


245 mm (9.65 in) 




Spring rate: Kl 


3.75 N/mm (0.375 kg/mm, 21 .0 lb/in) 




K2 


4.90 N/mm (0.5 kg/mm, 28.0 lb/in) 




Stroke K1 


0- 78 mm (0- 3.07 in) 




K2 


78- 140 mm (3.70-5.51 in) 




Optional spring 


No. 




Oil capacity 


619 cm 3 (21.8 I mpoz, 20.9 USoz> 




Oil level 


123 mm (4.8 in) 




Oil grade 


Yamaha fork oil lOwt or equivalent 




Enclosed air pressure (standard) 


39.2 kPa (0.4 kg/cm 2 , 5.7 psi) 




<Min. - Max.> 


39.2-98.1 kPa (0.4- 1.0 kg/cm 2 , 5.7 - 


14.2 psi) 


Front disc brake: 






Type 


Dual 




Disc outside diameter x thickness 


298x5.0 mm (11.7x0.20 in) 




Pad thickness Inner 


5.0 mm (0.20 in) 




<l_imit>.# 


0.5 mm (0.02 in) 




Pad thickness Outer 


5.0 mm (0.20 in) 




<Limit>* i 


f 
■ * 


0.5 mm (0.02 in) 
15.87 mm (0.63 in) 




r-Vv-V-.r-v,:.^! 


I I 

Master cylinder inside dian 


\ 
leter 


Caliper cylinder inside diameter 


33.96 + 30.23 mm (1.33+ 1.19 in) 




Brakefluid type 


DOT#4orDOT#3 





MAINTENANCE SPECIFICATIONS 



SPEC 



ft 



ELECTRICAL 



Model 



VMX12E/EC 



T.C.I.: 
Pickup coil resistance (color) 
T.C.I. Unit-model/Manufacturer 



81 -121Q at 20°C(68°F) (Black-Orange) 
TID14-93/HITACHI 



A.C. magneto: 
Model/Manufacturer 
Normal output 



FL130-06/H1TACHI 
14V, 25A at 5,000 r/min 



< 

— 30 

4— » 

c 
o 

3 20 

■*-' 

a. 

a 10 
O 



i ! 1 1 1 1 1 1 1 J 1 — 



Stater coil resistance 



12 3 4 5 6 

Engine speed (xlO 3 r/min) 
0.26 - 0.35Q at 20°C (White -White) 



Starter relay: 
Model/Manufacturer 
Amperage rating 
Coil winding resistance 



MS5D-191/HITACHI 

1COA 

3.9 ~ 4.7Q at 20°C (68°F) 



Flasher relay: 

Type 

Model/Manufacturer 
Self cancelling device 
Flasherfrequency 
Wattaae 



Semi transister type 

FX257N/N1PPONDENSO 

Yes. 

75 ~ 95cycle/min 

21wx2 + 3.4W 



Self cancelling unit: 
Model/Manufacturer 



FB257H/NIPPONDENSO 



FRONT AND REAR BRAKE 



CHASSIS 

FRONT AND REAR BRAKE 

©Air bleed screw (7) Pad spring 

(D Retaining pin © Caliper assembly 

(3) Dust seal © Brake disc 

@ Piston seat |_| The arrow mark on the pad spring must 

© Piston point i n the disc rotating direction. 

© Brake pad 



CHAS 



#%> 



FRONT CALIPER 



B 


PAD WEAR LIMIT: 
0,5 mm (0.02 in) 








c 


MINIMUM DISC THICKNESS: 
4.5 mm (0.18 in) 


D 


MAXIMUM DEFLECTION: 
0.3 mm (0.01 in) 



5 Nm (0.5 m • kg, 3.6 ft • lb) ] 



35 Nm (3.5 m -kg, 25 ft- lb) | 



20 Nm (2.0 m ■ kg, 1 4 ft - lb) 








E PAD SPRING 




COjTTED 
CLTH mTD 



^\ & 



-6- 



FRONT FORK 



§ha§Ig£%I 



FRONT FORK 

© Front fork assembly 
(D Innerfork tube 
(3) Piston metal 
@ Dust cover 
(5) Retaining clip 
(D Oil seal 
(7) Seal spacer 
© Slide metal 



(D Outer fork tube 
® Oil lock piece 
(fp Damper rod 
@ Fork spring 
(§) Spring seat 
@ Collar 
© Cap bolt 
(j§) Fork cap 



A 


FORK OIL {EACH}: 


B 


CAPACITY: 

619 cm 3 (21.8 Imp oz„ 20.9 US oz) 


C 


GRADE: 

Yamaha Fork Oil 10wt or equivalent 




STD. AIR PRESSURE: 

39.2 kPa (0.4 kq/cm 2 , 5.7 psi) 


E 


MIN. TO MAX. AIR PRESSURE: 

39.2 -98.1 kPa 

(0.4 _ 1 .0 kg/cm 2 , 5.7 - 14.2 psi) 



23 Nm (2.3 m • kg, 17 ft ■ lb) 



FORK SPRING FREE 
LENGTH (LIMIT): 
381.5 mm (15.0 in) 





23 Nm(2.3m» kg, 17 ft* lb)] 



-n 




/§»--© 



//h ' 



11/ 

i : ' 

! Li 




a) IBM 




— ' w , 

^ — ©EEffl /' 




20 Nm (2.0 m • kg, 1 4 ft • ibTT ""'^-^-^ 



62 Nm (6.2 m ■ kg, 45 ft • lb) 



-7- 



FRONT FORK 



CHAS 



(&b 



REMOVAL 



A WARNING 



Securely supportthe motorcycle so there is 
no danger of itf ailing over. 




IPIacethe motorcycle on a level place. 
2. Elevate thefrontwheel by placing suitable 
stand underthe engine. 

3. Remove: 

• Caliper assembly© 

• Brake hose holder© 

4. Disconnect: 

• Speedometer cable (3) 

NOTE: 

Do not depress the brake lever when the 
wheel is off the motorcycle otherwise the 
brake pads will be farced shut. 

5. Loosen: 

• Pinch bolt© (wheel axle) 

6. Remove: 

• Wheel axle© 

• Frontwheel assembly 



7. Remove: 

• Frontfender © 

• Fork brace© 




8. Remove: 

• Fork cap © 
Depress the valve © until all of the air has 

been released. 



FRONT FORK 



CHAS 



<#3& 




9. Loosen: 

• Pinch bolt© (handle crown) 

• Cap bolt© 

• Pinch bolts (3) (under bracket) 



A WARNING 



Support the fork before loosening the pinch 
bolts. 



DISASSEMBLY 

1. Remove: 

• Cap bolt® 

• Spacer© 

• Spring seat® 

• Spring (4) 

2. Drain: 

• Fork oil 

3. Remove: 

• Dust seal 

• Retaining clip 

Use a thin slotted head screw driver. 

CAUTION: 



Take care not to scratch the inner tube. 



4. Remove: 

• Bolt (damper rod) 

• Copper washer 



NOTE: 

Loosen the bolt (damper rod) while holding 
the damper rod with theT-handle and holder. 




T-handle: 
YM-01326 
90890-01326 

Holder (29 mm): 
YM-33962 
90890-01375 



5. Remove: 

• Innerfork tube 



-9- 



FRONT FORK 




CHAS 



(£%► 



************************************* 

Removal steps: 

• Hold the fork leg horizontally. 

• Clamp the caliper mounting boss of the 
outer tube securely i n a visewith soft jaws. 

• Pull out the inner fork tube from the outer 
tube by forcefully, butcarefully, with draw- 
ingthe inner tube. 

CAUTION: 

• Excessive force will damage the oil seal 
and/or the bushes. Damage oil seal and 
bushing must be replaced. 

• Avoid bottoming the innertu be inthe outer 
tube duringthe above procedure, astheoil 
lock piece will be damaged. 

************************************* 





6. Remove: 

• Oil seal 

• Seal spacer© 

• Slide metal© 

• Piston metal 

• Damper rod 

• Oil lock piece 



INSPECTION 
1. Inspect: 

• Innerfork tube 

• Outer fork tube 
Scratches/Bends/Damage 



Replace. 



A WARNING 



Do not attempt to straighten a bent inner 
fork tube as this may dangerously weaken 
the tube. 




Fork spring free length (limit): 
381.5 mm (15.0 in) 



-10- 



FRONTFORK 



CHAS 



g£% 





§ 



3. Inspect: 
• Damper rod 

Wear/Damage -» Replace. 

Contamination— > Blowout all oil passages 

with compressed air. 



4. Inspect: 

• Oil lock piece 

• O-ring (cap bolt) 
Wear/Damage -^ Replace. 



ASSEMBLY 

Reverse the "DISASSEMBLY" procedure. 

Note the following points. 



NOTE: 

• In front fork reassembly, be sure to use 
following new parts. 

* Piston metal 

* Slide metal 

* Oil seal 

* Dust seal 

• Make sure that all components are clean 
before reassembly. 



1. Install: 

• Damper rod 

CAUTION: 

Allow the damper rod to slide slowly down 
the inner fork tube until it protrudes from the 
bottom, being careful not to damage the 
inner fork tube. 



-11- 



FRONTFORK 



CHAS 



(£% 




2. Lubricate: 

• Innerfork tube (outer surface) 



Recommended lubricant: 
Fork oil 10w or equivalent 



3. Install: 

• Piston metal (f) 

• Oil lock piece© 

4. Tighten: 

• Bolt (damperrod) 




Bolt (damper rod): 

62 Nm (6.2 m • kg, 45 ft • lb) 
LOCTITE® 



NOTE: 

Tighten the bolt (damper rod)while holding 
the damper rod with theT-handle and holder. 




T-handle: 
YM-01326 




5.lnstall: 

• Slide metal 

• Seal spacer 
» Oil seal© 

Usetheforkseal driverweight and adapter 




Fork seal driver weight: 

YM-33963 

90890-01367 
Adapter (43 mm): 

YM-8020 

90890-01374 



^ 



NOTE: 

Beforeinstallingthe oil seal, apply the lithium 
soap base grease onto the oil seal lips. 



Be sure that the oil seal numbered side face 
upward. 



-12- 



FRONT FORK 



CHAS 



(^% 







6.lnstall: 

• Retaining clip© 



NOTE: 

Fitthe retaining clip correctly in the groove in 
the outer tube. 



7.1nstall: 
• Dust seal © 
Use the fork seal driver weight. 



jt 



Fork seal driver weight: 
YM-33963 
90890-01367 



8. Fill: 
• Fork oil 



jft 



Each fork 
619 cm 3 

(21.8 Imp oz,20.9 USozj 
Fork oil 10w or equivalent after 
filling, slowly pump the fork up 
and down to distribute oil. 




Oil level: 

123 mm (4.8 in) 
from the top of inner fork tube 
fully compressed without spring. 



NOTE: 

Place the front fork on upright position. 




9. Install: 

• Fork spring © 

• Spring seat© 

• Spacer collar© 

• Cap bolt© 

NOTE 

Fork 



-13- 



Fork spring must be installed with the 
smaller pitch upward. 

• Before installing the cap bolt, apply the 
grease to the O-ring. 

• Temporarily tighten the cap bolt. 



FRONT FORK 



CHAS 



<&%> 




INSTALLATION 

Reverse the "REMOVAL" procedure. 
Note the following points. 
1. Install: 
• Frontfork(s) 
Temporary tighten the pinch bolts. 



NOTE: 

Be sure the innerforktube end is flush with 
the top of the handle crown. 

2. Tighten 

• Pinch bolts© (under bracket) 

• Cap bolt© (frontfork) 

• Pjngh heU (3) % han.di£ erswn) 




Pinch bolt (lower bracket): 
23 Nm(2.3m. kg, 17 ft* lb) 

Cap bolt (frontfork): 

23 Nm (2.3m -kg, 17 ft • lb) 

Pinch bolt (handle crown): 
23 N m (2.3 nr kg, 17 ft • ib) 




3. Adjust: 

■ Frontfork air pressure 
Refer to FRONT FORK ADJUSTMENT" in 
the CHAPTER 2. 

4. Install: 

• Fork brace (?) 

• Frontfender (2) 



""> 



5.lnstall: 
■ Frontwheel 



""> 




Frontwheel axle: 

60 N m (6.0 m • kg, 43 ft • Ib) 
Pinch bolt (wheel axle): 

20 Nm (2.0m. kg, 14ft- Ib) 






-14- 



FRONT FORK 



CHAS 



#5g) 




6. Install: 

• Caliper assembly © 

• Brake hose holder (2) 

• Speedometer cable© 



\ 


Bolt (caliper bracket): 
35 Nm (3.5 m • kg, 25 ft • lb) 




A WARNING | 


Make sure that the brake hose are routed 
properly. 



r- 



-15- 



CIRCUIT DIAGRAM 



ELECTRICAL 
VMX12E/EC CIRCUIT DIAGRAM 



ELEC 


M 



© 



® 





© 




ON 


o 


o 


o 


OFF 








P 


o- 




-o 




! 


1 


1 



X 



R Br L 



b/r|w/b|y/l 
I b/y|w;r| 



© 



@ 
r/b| J_ 



-R/W- 



O— • R/B- 



(D 




R/W 

® 
L/W- 



I 



■=■ V© 



@ 



m?_ 



r/b R/e 

R/B 



B/YC^OL/Y- 



21 



R/W-l ^- Stl -K|_ L/ Y 

Sb- 
L/W • 



.28) 



g) L-0^O-Br-cr\i> Br- 



r@" 



m 



,W/Gr 



"Br 



Y/R Br/W 



N-L 



N-R 



OO 



oo 



OO 



OO 



OO 



&M 



I 



L/Y 



£1 



Sb+f© 



@ @ 



B/R 



i® 



L/W 

L/W A— 



W- 



® 



B/R 
B/Y 



L/Y 



©ta 



L/B _L 



R/B 



| L/B 



gTX 

Y * 



-0 



@ 



I 



Gy 



-W- 



<i OAP— •— Bf— »-• — 



FF^W* ?%? 



( *-R/W- 



-R/W- «-j 

H3--! 



:Ri 



© 



"i 



I >-R/W- 






"-R/W--f-, 



^ 



« 



-Bi 




G@ (/><* 

G 



L/R L L <*- Y 4 G/R 



CT\J>- 

© 



-R/Y- 



L/B 



Ch Dg 





HI 



OO 



LO 



ojo 



Y G 



"®" 



fljf 

® @ 



-16- 



CIRCUIT DIAGRAM 



ELEC 


jU| 



(\) AC. Magneto generator 
(f) Rectifier/Regulator 

(3) Main fuse 

@ Main switch 

(5) Fuse (IGNITION) 

(D "ENGINE STOP" switch 

(7) Ignitor unit 

(8) Pick up coil 

(9) Pressure sensor 
© Ignition coil #1 
(Q) Ignition coil #2 
© Ignition coil #3 
© Ignition coil #4 
(3) Fuel pump relay 

© "FUEL (RESERVE)" switch 

® Fuel pump 

@ Starter motor 

© Starter relay 

© "START" switch 

© Starting circuit cut-off relay 

@ Diode 

© Clutch switch 

SSidestand switch 
Neutral switch 

% "NEUTRAL" indicator light 

@ Oil level gauge 

@ Diode assembly 

© "OIL LEVEL" warning indicator light 

© Fuse (SIGNAL) 

© Flasher relay 



@) Reed switch 

© "TURN" switch 

© "TURN" indicator light 

@ Front/Rear brake switch 

©Tail/Brake light 

© Horn 

@ "HORN" switch 

© Temperature meter 

©Thermo unit 

© "FUEL" indicator light 

© Fuel sender unit 

© Tachometer 

© Fuse (FAN) 

@ Thermo switch 

© Fan motor 

© Fuse (HEAD) 

@ Control unit 

@ Servo motor 

© "LIGHTS" (Dimmer)switch 

© Head light 

"HIGH BEAM" indicator light 
© Meter light 
© Auxiliary light 
@; Battery 



B 


Black 


B/Y 


Black/Yellow 


Br 


Brown 


Br/W 


Brown/White 


Ch 


Chocolate 


G/R 


Green/Red 


Dg 


Darkgreen 


G/Y 


Green/Yeliow 


G 


Green 


L/B 


Blue/Black 


Gy 


Gray 


L/R 


Blue/Red 


L 


Blue 


L/W 


Blue/White 





Orange 


L/Y 


Blue/Yellow 


P 


Pink 


R/B 


Red/Black 


R 


Red 


R/G 


Red/Green 


Sb 


Skv blue 


R/W 


Red/White 


W 


White 


R/Y 


Red/Yellow 


Y 


Yellow 


W/G 


White/Green 


B/R 


Black/Red 


Y/R 


Yellow/Red 



-17- 



IGNITION SYSTEM 



E 


1 1 


E 


] -4+v^E] J 


Li 


] • 







I.. 1 — 




m 3 


3 




i 






G 


y- a 


B — j+\ 


fr**- m 


-1 



H 



+v 



J 



+v 



ELEC 



IGNITION SYSTEM 

DIGITAL IGNITION CONTROL SYSTEM 
DESCRIPTION 

The electronic ignition that sparks the engine 

is computer controlled and operated by the 

digital CPU (microprocessor). It has a pre- 
programed ignition advance curve. 

This programed advance curve closely 
matches the spark timing to the engine's 
ignition requirements. Onlyone pickupcoil is 
neededto meetthe requirements of the digi- 
tal ignitor unit. 

The digital ignitor also includes the control 
unitforthe electric fuel pump. 



Clutch switch 
Side stand switch 
C] Pressure sensor 
)1 Pick up coil 
_ CPU (microprocessor) 
f] Digital ignitor unit 
Fuel pump 

Zl Fuel pump control relay 
T\ Ignition coil 



OPERATION 

The following operations are digitally-per- 
formed by signal from the pickup coil signal: 
1 .Determing proper ignition timing. 
2. Sensing the engine revolution speed. 

3. Determing timing for switching on ignition 
coil (duty control). 

4. Increasing ignition coil primary currentfor 
starting the engine. 

5. Sensing engine stall. 

6. Preventing over-revolution of the engine. 



^\ 



-18- 



1 



) 



7 



) 



) 



) 



\ 



VMX12E/EC WIRING DIAGRAM 




, UkaSfeUJ ff# sip nri ^fc- 
I [r^K^i rffi rIPi I* 1 




COLOR CODE 

B Black Br Brown 

I Blue Ch Chocolate 

G Green Gy .Gray 

Y Yellow Sb Sky blue 

R Red Dg Dark green 

P Pink W White 

Orange BA. Black/Blue 



B/V BlackA'ellow 

B/R Black/Red 

L/B Blue/Black 

UY Blue/Yellow 

L/W Blue/White 

G/Y .Green/Yellow 

G/R Green/Red 



Y/R Yellow/Red 

R/B Red/Black 

R/G Red/Green 

FVY .RedA'ellow 

R/W Red/white 

Br/W Brown/White 

W/B .White/Black 



W/G .White/Green 

W/R White/Red 

Y/L .Yellow/Blue 



© 
© 
© 
8 
® 
@ 
@ 
@ 
© 
® 



@ 



® 

® 



@ 



Clutch switch 

'LIGHTS' (Dimmer) switch 

'HORN' switch 

TURN' switch 

Temp, meter 

Tachometer 

Meterlight 

"HIGH BEAM' 

TURN' 

'FUEL' 

'OIL LEVEL' 

'NEUTRAL' 

Front flasher light(L) 

Headlight 

Front flasher light (R) 

'START switch 

'ENGINE STOP' switch 

'FUEL' switch 

Front brake switch 

Speedometer 

Meterlight 

Main switch 

1gn1tor 

Thermo switch 

Thermo unit 

Fan motor 

Ignitioncoil 

Spark plug 

Fuel sender 

Rear brake switch 

Starter relay 

Starter motor 

Battery 

Main fuse 

Earth 

Fuse 

Rearflasher light(R) 

Tail/Brake light 

Rearflasher light(L) 

Neutral switch 

Oil level gauge 

Rectifier/Regulator 

AC Magneto/Pick up coil 

Sidestand switch 

Fuel pump 

Control unit 

Pressure sensor 

Control unit 

Servo motor 

Flasher relay 

Starting circuit cut off relay 

Diode ass'y 

Horn 



•~s 



VAMAHA MOTOR CO..LTD. 



PRINTED IN U.S.A. 




YAMAHA 



VNIK12U 
VMX12UC 



Supplementary 
Service Manual 



i 







7 



LIT-11616-06-08 



FOREWORD 

This Supplementary Service Manual has been prepared to introduce new service and new data for the 
VMX12U/UC. For complete information on service procedures, it is necessary to use this Supplemen- 
tary Service Manual together with following manual: 



VMX12N/NC Service Manual: LIT-11616-04-67 

VMX12S/SC Supplementary Service Manual: LIT-1 1 61 6-04-98 



VMX12U/UC 

SUPPLEMENTARY SERVICE MANUAL 

© 1987 by Yamaha Motor Corporation U.S.A. 

1st Edition, August 1987 

All rights reserved. Any reprinting or 

unauthorized use without the written 

permission of Yamaha Motor Corporation U.S.A, 

is expressly prohibited. 

Printed in U.S.A. 
P/N LIT-11616-06-08 



NOTICE 

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and 
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, 
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor- 
cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle 
repair technology. Without such knowledge, attempted repairs or service to this model may render 
it unfit to use and/or unsafe. 

This model has been designed and manufactured to perform within certain specifications in regard to 
performance and emissions. Proper service with the correct tools is necessary to ensure that the 
motorcycle will operate as designed. If there is any question about a service procedure, it is impera- 
tive that you contact a Yamaha dealer for any service information changes that apply to this model. 
This policy is intended to provide the customer with the most satisfaction from his motorcycle and 
to conform with federal environmental quality objectives. 

Yamaha Motor Company, Ltd. is continually strivingto improveall models manufactured by Yamaha. 
Modifications and significant changes in specifications or procedures will be forwarded to all 
Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. 



NOTE: 

This Service Manual contains information regarding periodic maintenance to the emission control 
system for the VMX12N/NC. Please read this material carefully. 

TECHNICAL PUBLICATIONS 

SERVICE DIVISION 

MOTORCYCLES OPERATIONS 

YAMAHA MOTOR CO., LTD. 

HOW TO USE THIS MANUAL 

PARTICULARLY IMPORTANT INFORMATION 

This material is distinguished by the following notations. 

NOTE: A NOTE provides key information to make procedures easier or clearer. 

A CAUTION indicates special procedures that must be followed to avoid damage to 
the motorcycle. 



WARNING: 



A WARNING indicates special procedures that must be followed to avoid injury to a 
motorcycle operator or person inspecting or repairing the motorcycle. 



MANUAL FORMAT 

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- 
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains 
comprehensive explanations of all disassembly, repair, assembly, and inspection operations. 
In this revised format, the condition of a faulty component will precede an arrow symbol and the 
course of action required will follow the symbol, e.g., 
• Bearings: 
Pitting/Damage-^ Replace. 

EXPLODED DIAGRAM 

Each chapter provides exploded diagrams before each disassembly section for ease in identifying 
correct disassembly and assembly procedures. 









© 


2) 


ILLUSTRATED SYMBOLS 
(Refer to the illustration) 


Sl^O 


#^ 


INSP 


fc* 


ADJ 


^ 




Illustrated symbols (t) to (8) are designed as 






thumb tabs to indicate the chapter's number and 


lo 


3) 


content. 


ENG 


V 


COOL 


X 


(T) General information 

(§) Periodic inspection and adjustment 






(3) Engine 

(4) Cooling system 
(D Carburetion 


© 


D 


CARB 


f 


|CHAs|<3^5fe| 


© Chassis 
(7) Electrical 
(D Appendices 








© 


$ 




ELEC 


^3 


APPX 


IN 










® 












Illustrated symbols (9) to ($ are used to iden- 




*& 






^ 




tify the specifications appearing. 

(9) Filling fluid 
© Lubricant 














©Tightening 
©Wear limit, clearance 


<o 






© 








6 






3 




© Engine speed 
<8>fi.V, A 
















@ 






© 










A 


























© © © 
Q © © 


Illustrated symbols © to (£}) in the exploded 
diagram indicate grade of lubricant and location 
of lubrication point. 

©Apply engine oil 

©Apply gear oil 

@ Apply molybdenum disulfide oil 

(3) Apply wheel bearinggrease 

©Apply lightweight lithium-soap base grease 

@ Apply molybdenum disulfide grease 

© Apply locking agent (LOCTITE® } 


® @ © 















~\ 



« 



MOTORCYCLE IDENTIFICATION 




GEN 
INFO 



#^ 




GENERAL 
INFORMATION 

MOTORCYCLE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number© is stamped 
into the steering head pipe. 

NOTE: 

The vehicle identification number is used to 
identify your motorcycle and may be used to 
register your motorcycle with the licensing 
authority in your state. 



Starting Serial Number: 

VMX12U JYA2WEE0 *JA000101 

VMX12UC JYA2WFC0 *JA000101 



ENGINE SERIAL NUMBER 

The engine serial number (T) is stamped into the 
left side of the engine. 



NOTE: 

The first three digits of these numbers are for 
model identifications; the remaining digits are 
the unit production number. 



Starting Serial Number: 

VMXI2U 2WE-000101 

VMX12UC 2WF-000101 



NOTE: 

Designs and specifications are subject to change 
without notice. 




SPECIFICATION 



APPX 



IS 



APPENDICES 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



Model 


VMX12U/UC 


Model Code Number 
Engine Starting Number 
Vehicle Identification Number 


2WE VMX12UC: 2WF 
2WE-000101 VMX12UC: 2WF-000101 
JYA2WEEO *JA000101 
VMX12UC: JYA2WFC0 *JA000101 


Basic Weight: 
Weight Oil and Full Fuel Tank 


283 kg (624 lb) 
VMX12UC: 284 kq (626 lb) 


Tire Pressure (Cold Tire): 
Basic Weight: 

With Oil and Full Fuel Tank 
Maximum Load* 

Cold Tire Pressure: 
Upto90kg (1981b) Load* 

90 kg (1981b)* ~ Maximum Load* 
High Speed Riding 


283 kg (624 lb) VMX1 2UC: 284 kg (626 lb) 
216 kg (476 lb) VMX12UC: 215 kg (474 lb) 


FRONT 


REAR 


235 kPa 
(2.4 kg/cm 2 , 34 psi) 


255 kPa 

(2.6 kg/cm 1 , 36 psi) 


235 kPa 

(2.4 kg/crn\ 34 psi) 


275 kPa 

(2.8 kg/cm % , 40 psi) 


235 kPa 
(2.4 kg/cm 2 , 34 psi) 


255 kPa 
(2.6 kg/cm 2 , 36 psi) 




Brake: 
Front 
Operation 
Rear 

Operation 
Brake Fluid 


Dual disc brake 

Right hand operation 

Single disc brake 

Right foot operation 

DOT #4 (If DOT #4 is not available #3 can 

be used.) 



MAINTENANCE SPECIFICATIONS 
Engine 



Model 


VMX12U/UC 


Camshaft: 
Drive Method 
Cam Cap Inside Dia. 
Camshaft Outside Dia. 
Shaft-to-Cap Clearance 
Cam Dimensions 
Intake "A" 

< Limit> 

Intake "B" 

< Limit> 


1 


Chain drive (Center) 

25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 
24.967 ~ 24.980 mm (0.9830 ~ 0.9835 in) 
0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) 

36.25 ~ 36.35 mm (1.427- 1.431 in) 

< 36.15 mm (1.423 in)> 

28.02 "28.12 mm (1.103- 1.107 in) 

< 27.92 mm (1.099 in) > 

VMX12UC: 

27.97 ~ 28.07 mm (1.101 ~ 1.105 in) 

< 27.87 mm (1.097 in) > 


a 




• 













-2 







SPECIFICATION 


APPX 


i\ 






Model 


VMX12U/UC 


Exhaust "A" 




36.25 - 36.35 mm (1.427- 1.431 in) 




< Limit > 




< 36.15 mm (1.423 in)> 




Exhaust y 'B" 




28.02 - 28.12 mm (1.103- 1.107 in) 




< Limit > 




< 27.92 mm (1.099 in)> 
VMX12UC: 

27.97- 28.07 mm (1.101 - 1.105 in) 

< 27.87 mm (1.097 in)> 




Camshaft Runout Limit 




0.03 mm (0.0012 in) 




Carburetor: 








I.D. Mark 




1FKOO VMX12UC:2WF00 




Main Jet 


(M.J.) 


# 152.5 




Main Air Jet 


(M.A.J.) 


4>2.0 




Jet Needle 


(J.N.) 


5EZ43 VMX12UC:5EZ50 




Needle Jet 


(N.J.) 


Y-0 




Pilot Jet 


(P.J.) 


#37.5 




Pilot Air Jet 


(P.AJ.) 


#90 VMX12UC:#100 




Pilot Screw 


(P.S.) 


Preset 




Pilot Outlet 


(P.O.) 


0.9 




Bypass 


(B.P. 1) 


0.8 






(B.P. 2) 


0.8 






(B.P. 3) 


0.9 




Valve Seat Size 


(V.S.) 


1.5 




Starter Jet 


(G.S.1) 


#45 






(G.S.2) 


#0.8 




Fuel Level 




15.5 - 16.5 mm (0.61 " 0.65 in) 




Engine Idling Speed 




950- 1,050 r/min 

VMX12UC: 1,050- 1,150 r/min 




Vacuum Pressure at Idling 


Speed 


Above 200 mm Hg (7.90 in Hg) 




Vacuum Synchronous Difference 


Below 20 mm Hg (0.79 in Hg) 





-3- 



fv 




YAMAHA MOTOR CO., LTD. 



IWATA, JAPAN 



PRINTED IN U.S.A. 




YAMAHA 



VMX12S 
VMX12SC 



Supplementary 
Service Manual 







LIT-11616-04-98 



FOREWORD 



VMX12N/NC Service Manual: LIT-1 1616-04-67 



VMX12S/SC 

SUPPLEMENTARY SERVICE MANUAL 

© 1985 by Yamaha Motor Corporation U.S.A. 

1st Edition, September 1985 

All rights reserved. Any reprinting or 

unauthorized use without the written 

permission of Yamaha Motor Corporation U.S.A. 

is expressly prohibited. 

Printed in U.S.A. 
P/N LIT-1 161 6-04-98 



"> 



NOTICE 

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and 
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, 
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor- 
cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle 
repair technology. Without such knowledge, attempted repairs or service to this model may render 
it unfit to use and/or unsafe. 

This model has been disgned and manufactured to perform within certain specifications in regard to 
performance and emissions. Proper service with the correct tools is necessary to ensure that the 
motorcycle will operate as designed. If there is any question about a service procedure, it is impera- 
tive that you contact a Yamaha dealer for any service information changes that apply to this model. 
This policy is intended to provide the customer with the most satisfaction from his motorcycle and 
to conform with federal environmental quality objectives. 

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. 
Modifications and significant changes in specifications or procedures will be forwarded to all 
Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. 

NOTE: 

This Service Manual contains information regarding periodic maintenance to the emission control 
system for the VMX12N/NC. Please read this material carefully. 

TECHNICAL PUBLICATIONS 

SERVICE DIVISION 

MOTORCYCLES OPERATIONS 

YAMAHA MOTOR CO., LTD. 

HOWTO USE THIS MANUAL 

PARTICULARLY IMPORTANT INFORMATION 

This material is distinguished by the following notation. 

NOTE: A NOTE provides key information to make procedures easier or clearer. 

A CAUTION indicates special procedures that must be followed to avoid damage to 
the motorcycle. 



WARNING: 



A WARNING indicates special procedures that must be followed to avoid injury to 
a motorcycle operator or person inspecting or repairingthe motorcycle. 



MANUAL FORMAT 

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- 
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains 
comprehensiveexplanationsof all disassembly, repair, assembly, and inspection operations. 
In this revised format, the condition of a faulty component will precede an arrow symbol and the 
course of action requiredwill follow the symbol, e.g., 
• Bearings 

Pitting/Damage * Replace. 

EXPLODED DIAGRAM 

Each chapter provides exploded diagrams before each disassembly section for ease in identifying 
correct disassembly and assembly procedures. 









© 


© 


ILLUSTRATED SYMBOLS 
(Refer to the illustration) 


GEN 
INFO 


<?^ 


INSP i 


ft 


ADJ ' 


Illustrated symbols \'l_) to ® are designed as 






thumb tabs to indicate the chapter's number 


© 


© 


and content. 


ENG 


^^ 


COOL ( 


K 


(T) General information 

(2) Periodic inspection and adjustment 






(D Engine 


© 


6 


(4) Cooling system 
©Carburetion 


CARB 


* 


IcHASefafel 


©Chassis 
©Electrical 
(D Appendices 








© 


© 




ELEC 


u 


APPX i 


■\ 


Illustrated symbols © to ® are used to 
identify the specifications appearing. 








© 






t~\ 






©Filling fluid 


*& 




(10, 


^ 


= 


(UP Lubricant 
©Tightening 
©Wear limit, clearance 
©Engine speed 














®n,v, a 


© 






© 










^ 






£ 


< 


Illustrated symbols © to © in the ex- 
ploded diagram indicate grade of lubricant 














© 






(14) 






and location of lubrication point. 




A 








a. 




©Apply engine oil 

©Apply gear oil 

©Apply molybdenum disulfide oil 














©Apply wheel bearing grease 
(fi) Apply lightweight lithium-soap base grease 
@) Apply molybdenum disulfide grease 
©Apply locking agent (LOCTITE®) 


Q Q Q 


© © © 

















MOTORCYCLE IDENTIFICATION 



iftFO^ 





GENERAL 
INFORMATION 

MOTORCYCLE I DENTI FlCATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number (T) is stamped 
intothe steering head pipe. 

NOTE: 

The vehicle identification number is used to 
identify your motorcycle and may be used to 
register your motorcycle with the licensing 
authority in your state. 



Starting Serial Number: 

VMX12S JYA1UTOO*GAOOOI01 

VMX12SC JYA1UR00-*GAOOOI01 



ENGINE SERIAL NUMBER 

The engine serial number (T) is stamped intothe 
leftside of the engine. 



NOTE: 



Starting Serial Number: 

VMX12S 1UT-000101 

VMX12SC 1UR-000101 



NOTE: 

Designs and specifications are subject to change 
without notice. 




- 1 - 



APPX 



iS 



SPECIFICATIONS 



SPECIFICATIONS 
GENERAL SPECI FICATIONS 



APPENDICES 



Model 



Model Code Number 
Engine Starting Number 
Vehicle Identification Number 



Dimensions: 
Overall Length 
Overall Width 
Overall Height 
Seat Height 
Wheel base 
Minimum Ground Clearance 



Basic Weight: 
Weight Oil and Full Fuel Tank 



Minimum Turning Radius: 



Engine: 
Engine Type 
Cylinder Arrangement 
Displacement 
Bore x Stroke 
Compression Ratio 
Compression Pressure 
Starting System 



Lubrication System: 



Oil Type or Grade: 
Engine Oil 

30 40 



50 60 °F 



10 15°C 



Final Gear Oil 



Oil Capacity: 
EngineOil: 
Periodic Oil Change 
With Oil Filter Replacement 
Total Amount 
Final Gear Case: 
Total Amount 



Radiator Capacity: 
(Including All routes) 



Air Filter: 



Fuel: 
Type 

Tank Capacity: 
Total 
Reserve 



~>l 



VMX12S/SC 



1UT VMX12SC: 1UR 

1UT-000101 VMX12SC: 1UR-000101 

JYA1UT00 * GA000101 
VMX12SC: JYA1UR00 -* GA000101 



2,300 mm (90.6 in) 
795 mm (31.3 in) 

1,160 mm (45.7 in) 
765 mm (30.1 in) 

1,590 mm (62.6 in) 
145 mm ( 5.7 in) 



282 kg (622 lb) 
VMX12SC: 283 kq (624 lb) 



2,790 mm (110 in) 



Liquid cooled 4-stroke gasoline, DOHC 

V-4 cylinder 

1,198 cm 3 

76 x 66 mm (2.992 x 2.598 in) 

10.5 : 1 

1,422 kPa (14.5 kg/cm 2 ,206 psi) 

Electric starter 



"" 



Wep sump 



Yamalube 4-cycle oil or SAE 20W40 type SE 
motor oil (If temperature does not go below 
5°C (40°F)) 

SAE 10W30type SE motor oil (If temperature 
does not go above 1 5°C (60"F ) ) 

SAE 80 API "GL-4" Hypoid gear oil 



~> 



3.5 L (3.1 Impqt, 3.7 US qt) 

3.8 L (3.3 Impqt, 4.0 USqt) 

4.7 L (4.1 Impqt, 5.0 USqt) 

0.2 L (0.18 Impqt, 0.21 USqt) 



*"> 



3.05 L (2.69 Impqt, 3.22 USqt) 



Dry type element 



Regular gasoline 

15.0 L (3.3 Imp gal, 4.0 US gal) 
3.0 L (0.66 Imp gal, 0.80 US gal) 



2- 





SPECIFICATIONS 


APPX 


IN 






Model 


VMX12S/SC 


Carburetor: 
Type/Manufacturer 


BDS34x4/MIKUNI 


Spark Plug: 
Type/Manufacturer 
Gap 


DPR8EA-9/NGK,X24EPR-U9/NIPPONDENSO 
0.8 " 0.9 mm (0.031 ~ 0.035 in) 


2lutch Type: 


Wet, multiple-disc 


Transmission: 
Primary Reduction System 
Primary Reduction Ratio 
Secondary Reduction System 
Secondary Reduction Ratio 
Transmission Type 
Operation 
Gear Ratio: 

1st 

2nd 

3rd 

4th 

5th 


Spar gear 

87/49 ( 1 .775) 

Shaft drive 

21/27 x33/9 (2.851) 

Constant mesh, 5-speed 

Left foot operation 

43/17 (2.529) 
39/22(1.772) 
31/23 (1.347) 
28/26(1.076) 
26/28 (0.928) 


Chassis: 
Frame Type 
Caster Angle 
Traii 


Double cradle 

29" 

119mm (4.7 in) 


Tire: 
Type 
Size(F) 

Size(R) 

Wear Limit 


Tubeless 
110/90V18 

BRIDGESTONEG525AW/DUNLOP F20 
150/90V15 

BRIDGESTONEG526BW/DUNLOP K525 
1.0 mm (0.04 in) 


Tire Pressure (Cold Tire): 
Basic Weight: 

With Oil and Full Fuel Tank 
Maximum Load* 

Cold Tire Pressure: 
Upto90kg (1981b) Load* 

90kg (1981b)* "216kg (4761b) Load* 

High Speed Riding 


282 kg (622 lb) VMX12SC: 283 kg (624 lb) 
216 kg (476 lb) 


FRONT 


REAR 


235 kPa 
(2.4 kg/cm 2 , 34 psi) 


255 kPa 
(2.6 kg/cm 2 ,36 psi) 


235 kPa 
(2.4 kg/cm 2 , 34 psi) 


275 kPa 
(2.8 kg/cm 2 , 40 psi) 


235 kPa 
(2.4 kg/cm 2 , 34 psi) 


255 kPa 
(2.6 kg/cm 2 , 36 psi) 




Brake: 
Front 
Operation 
Rear 
Operation 


Dual disc brake 
Right hand operation 
Single disc brake 
Rightfoot operation 


Suspension: 
Front Suspension 
Rear Suspension 


Telescopic fork 
Swing arm 



-3- 




YAMAHA MOTOR CO., LTD. 



IWATA. JAPAN 



PRINTED IN U.S.A. 




YAMAHA 



VMK12N 
VMN12NC 



Service Manual 







LIT-1 1616-04-67 



VMX12N/VMX12NC 
SERVICE MANUAL 

1st Edition- December 1984 
2nd Printing- September 1985 JEM B 171 



ALL RIGHTS RESERVED BY 
YAMAHA MOTOR CORPORATION, U. 
CYPRESS, CALIFORNIA 90630 

LIT-11616-04-67 



S. A. 



-~> 



"> 



NOTICE 

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and 
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, 
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor- 
cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle 
repair technology. Without such knowledge, attempted repairs or service to this model may render 
it u nf it to use and/or unsafe. 

This model has been disgned and manufactured to perform within certain specifications in regard to 
performance and emissions. Proper service with the correct tools is necessary to ensure that the 
motorcycle will operate as designed, If there is any question about a service procedure, it is impera- 
tive that you contact a Yamaha dealer for any service information changes that apply to this model. 
This policy is intended to provide the customer with the most satisfaction from his motorcycle and 
to conform with federal environmental quality objectives. 

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. 
Modifications and significant changes in specifications or procedures will be forwarded to all 
Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. 

NOTE: 

This Service Manual contains information regarding periodic maintenance to the emission control 
system for the VMX12N/NC. Please read this material carefully. 

TECHNICAL PUBLICATIONS 

SERVICE DIVISION 

MOTORCYCLES OPERATIONS 

YAMAHA MOTOR CO., LTD. 

HOW TO USE THIS MANUAL 

PARTICULARLY IMPORTANT INFORMATION 

This material is distinguished by the following notation. 

NOTE: A NOTE provides key information to make procedures easier or clearer. 

A CAUTION indicates special procedures that must be followed to avoid damage to 
the motorcycle. 



WARNING: 



A WARNING indicates special procedures that must be followed to avoid injury to 
a motorcycle operator or person inspecting or repairing the motorcycle. 



MANUAL FORMAT 

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- 
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains 
comprehensive explanations of all disassembly, repair, assembly, and inspection operations. 
In this revised format, the condition of a faulty component will precede an arrow symbol and the 
course of action required will follow the symbol, e.g., 
• Bearings 

Pitting/Damage -» Replace. 

EXPLODED DIAGRAM 

Each chapter provides exploded diagrams before each disassembly section for ease in identifying 
correct disassembly and assembly procedures. 









© 


© 


ILLUSTRATED SYMBOLS 
(Refer to the illustration) 


GEN 
INFO 


^^ 


INSP 


mfc 




ADJ 


^ 




Illustrated symbols©to(8)are designed as thumb 






tabs to indicate the chapter's number and 
content. 


© 


© 


ENG 


>• 


COOL 


K 


(T) General information 

(5) Periodic inspection and adjustment 

(3) Engine 






(A) Cooling system 


© 


© 


(5) Carburetion 

(6) Chassis 


CARB 


4 


CHAS 


(afcfe 


(7) Electrical 

(8) Appendices 








© 


© 




ELEC 


— 


APPX 


IS 












® 






Illustrated symbols (9)to (Q) are used to identify 


^ 




the specifications appearing in the text. 

(9) Fillingfluid 

(Up Lubricant 

(}j) Tightening 

(f|) Wear limit, clearance 

(jj) Engine speed 

<3>ft, V, A 








£b 






© 








6 




% 


















© 






© 










A 






|FH| 
1- 55 * 










1 








© | © i © i 

Q Q Ci 


Illustrated symbols <0D to @ in the exploded dia- 
gram indicate grade of lubricant and location of 
lubrication point. 

(J!) Apply engine oil 

@ Apply gear oil 


© © @ 


(Q) Apply molybdenum disulfide oii 

(jj! Apply wheel bearing grease 

(f|) Apply lightweight lithium-soap base grease 

@) Apply molybdenum disulfide grease 

© Apply locking agent {LOCTITE®) 


© 













Being a Yamaha owner, you obviously prefer 
a quality product. 



genuine 

adj. 1 . Real 2. Authentic, 
not artificial 3. Yamaha. 

GENUINE YAMAHA PARTS & ACCESSORIES 



Don't compromise the quality and 
performance of your Yamaha with off-brand 
alternatives. You'll be getting exactly what 
you're paying for. 






^ 



-~\ 



"■> 



INDEX 



GENERAL INFORMATION 



WFO 




PERIODIC INSPECTIONS 
AND ADJUSTMENTS 



INSP 
ADJ 




ENGINE OVERHAUL 



ENG 



H 



COOLING SYSTEM 



CARBURETION 



X 



coolF^ 




CARBpj 



CHASSIS 



ELECTRICAL 



CHAS|^ 



ELEC 




APPENDICES 



1\ 



GEN 
INFO 



#^ 



CHAPTER 1. 
GENERAL INFORMATION 



MOTORCYCLE IDENTIFICATION 1-1 

VEHICLE IDENTIFICATION NUMBER 1-1 

ENGINE SERIAL NUMBER 1-1 

IMPORTANT INFORMATION 1-2 

ALL REPLACEMENT PARTS 1-2 

GASKETS. OIL SEALS. AND O-RINGS 1-2 

LOCK WASHERS/PLATES AND COTTER PINS 1-2 

BEARINGS AND OIL SEALS 1-2 

CIRCLIPS 1-3 

SPECIAL TOOLS 1-3 

FOR TUNE-UP 1-3 

FOR ENGINE SERVICE 1-4 

FOR CHASSIS SERVICE 1-8 

FOR MIDDLE GEAR SERVICE 1-9 

FOR ELECTRICAL COMPONENTS 1-10 



foFO^ 



MOTORCYCLE IDENTIFICATION 




GENERAL 
INFORMATION 

MOTORCYCLE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number is stamped 

into the steering head pipe. 

NOTE: 

The vehicle identification number is used to 
identify your motorcycle and may be used to 
register your motorcycle with the licensing 
authority in your state. 



Starting Serial Number: 

VMX12N JYA1FK00*FA000101 

VMX12NC JYA1JH00*FA000101 



■*> 




Starting Serial Number: 

VM^12N 1 FK-000101 

VM&12NC 1JH-000101 



NOTE: 

Designs and specifications are subject to change 
without notice. 




""> 



1-1 



IMPORTANT INFORMATION 



ftpo^ 



IMPORTANT INFORMATION 

ALL REPLACEMENT PARTS 
1. We recommend to use Yamaha genuine 
parts for all replacements. Use oil and/or 
grease recommended by Yamaha for assem- 
bly and adjustment. 



GASKETS, OIL SEALS, AND O-RINGS 

1. All gaskets, seals, and O-rings should be 
replaced when an engine is overhauled. All 
gasket surfaces, oil seal lips, and O-rings 
must be cleaned. 

2. Properly oil all mating parts and bearings 
during reassembly. Apply grease to the oil 
seal lips. 




LOCK WASH ERS/PLATES AND COTTER PINS 
1. All lock washers/plates ® and cotter pins 
must be replaced when they are removed. 
Lock tab(s) should be bent along the bolt 
or nut flat(s) after the bolt or nut has been 
properly tightened. 



BEARINGS AND OIL SEALS 
1. Install the bearing(s) (D and oil seal(s) (2) 
with their manufacturer's marks or numbers 
facing outward. (In other words, the 
stamped letters must be on the side exposed 
to view.) When installing oil seal(s), apply a 
light coating of light-weight lithium base 
grease to the seal lip(s). Oil the bearings 
liberally when installing. 

TION; 

Do not use compressed air to spin the bearings 
dry. This causes damage to the bearing surfaces. 



1-2 



GEN 
INFO 



#§ 



SPECIAL TOOLS 




CIRCLIPS 

1. All circlips should be inspected carefully 

before reassembly. Always replace piston 
pin clips after one use. Replace distorted 
circlips. When installing a circlip (T) , make 
sure that the sharp-edged corner (2) is 
positioned opposite to the thrust (3) it 
receives. See the sectional view. 

(4) Shaft 

SPECIAL TOOLS 

The proper special tools are necessary for com- 
plete and accurate tune-up and assembly. Using 
the correct special tool will help prevent damage 
caused by the use of impropertools or improvis- 
ed techniques. 




FOR TUNE UP 

1 . Inductive Tachometer 
P/N YU-08036 
This tool i s needed for detecting engine rpm. 



2. Inductive Timing Light 
P/N YU-08037 
This tool is necessary for checking ignition 
timing. 



3. Compression Gauge 
P/N YU-33223 
This gauge is used to measure the engine com- 
pression. 



1-3 



1 







1 



SPECIAL TOOLS 




4. Fuel Level Gauge 
P/N YM-01312-A 
This gauge is used to measure the fuel level 
in the float chamber. 




5. Vacuum Gauge 
P/N YU-08030 
This gauge is needed for carburetor synchro- 
nization. 



6. Radiator Cap Tester 

P/N YU-24460 
This tester is needed for checking the cooling 
system. 



FOR ENGINE SERVICE 

1. Clutch Holder 
P/N YM-9 1042 
This tool is used to hold the clutch when re- 
moving or installing the clutch boss locknut. 



2. Tappet Adjusting Tool 
P/N YM-33961 
This tool is necessary to replace valve adjusting 
pads. 



1-4 



GEN 
INFO 


$^ 


SPECIAL TOOLS 








€** 


3. Valve Spring Compressor 
P/N YM-04019 
This tool is needed to remove and install the 
valve assemblies. 




4. Valve Guide Remover (5.5 mm) 
P/N YM-01122 
This tool is used to remove the valve guides. 



5. Valve Guide Reamer (5.5 mm) 
P/N YM-01196 
This tool is used to rebore the new valve guide. 



^\ 



6. Valve Guide Installer 
P/N YM-01129 
This tool is needed to install the valve guides 
properly. 



7. Valve Seat Cutter Set 
P/N YM-9 1043 
This tool is needed to resurface the valve seat. 



1-5 



SPECIAL TOOLS 



INFO^ 






8. Flywheel Puller 
P/N YU-33270 - ® 
Adapter 

P/N YM-33282 - (f) 
These tools are used to remove the flywheel. 



9.8 mm Wrench Adapter 
P/N YM-28897 
This tool is used to loosen or tighten thecylinder 
head securing nut. 



10. Piston Ring Compressor 

P/N YM-8037 
This tool is used when installing the piston into 
the cylinder. 



1 1 . Water Pump Seal Installer 

Handle 

P/N YM-04085 - 1 - © 

Adapter 

P/N YM-33221 -(2) 
This tool is needed for proper installation of 
the water pump seal, 



12. Piston Pin Puller 

P/N YU-0 1304 
This tool is used to remove the piston pin. 



1-6 



GEN 
INFO 



dfo 



SPECIAL TOOLS 




13.#40Torx Driver 
P/N YU-29843-7 
This tool is used to loosen or tighten the middle 
gear bearing retainer bolt. 





14. #30 Torx Driver 
P/N YU-29843-6 
This tool is used to loosen or tighten the drive 
axle bearing retainer bolt. 



15. #25 Torx Driver 
P/N YU-29843-4 
This tool is used to loosen or tighten the shift 
cam segment securing bolt. 



16. Plastigage® Set "Green" 

P/N YU-33210 
This gauge is needed to measure the clearance 
for the connecting rod bearing. 



17. Special Torx Driver 

P/N YU-25359-2 
This tool is used when overhauling the car- 
buretors. 



1-7 



SPECIAL TOOLS 



GEN 
INFO 



#^ 





18. Sealant (Quick Gasket®) 

P/NACC-1 1001-05-01 
This sealant (bond) is used for crankcase mating 
surfaces, etc. 




FOR CHASSIS SERVICE 

1.T-Handle 

P/N YU-01326-G) 

Damper Rod Holder (24 mm) 

P/N YM-0 1328- <D 
This tool is used to loosen and tighten the 
front fork cylinder holding bolt. 



2. Front Fork Cap Socket (17 mm) 
P/N YM-01104 
This tool isneededwhen looseningand tightening 
the front fork cap bolt. 




3. Front Fork Seal Driver Weight 

P/N YM-33963 - © 

Adapter (40 mm) 

P/N YM-33964 -(£) 
These tools are used when installing the fork 
seal. 




4. Ring Nut Wrench 

P/N YU-01268 
This tool is used to loosen and tighten the 
steering ring nut. 



1-8 



"GEN 
INFO 



#^ 



SPECIAL TOOLS 








FOR MIDDLE GEAR SERVICE 

1. Universal Joint Holder 
P/N YM-04062 
This tool is used when adjusting the gear lash 
in the middle gear. 



2. Middle Drive Gear Holder 

P/N YM-33222 
This tool is needed when measuring the middle 

gear lash. 



3. Damper Spring Plate 
P/N YM-33286 
This tool is used with a middle drive gear holder 
to disassemble and reassemble the middle gear 
damper. 



4. Dial Gauge 
P/N YU-03097 
This tool is used to measure the gear lash for 
the middle gear and final gear. 



5. 55 mm Offset Wrench 
P/N YM-04054 
This tool is used to loosen and tighten the drive 
shaft nut. 



1-9 



SPECIAL TOOLS 




GEN 
INFO 



#^ 



6. Final Drive Shaft Holder 
P/N YM-01229 
This tool is used when adjusting the gear lash 
for the final gear. 



7. Final Drive Shaft Bearing Retainer Wrench 
P/N YM-04050 
This tool is used to remove and install the 
bearing retainer, 



8. Gear Lash MeasurementTool 

P/N YM-0 1230 
This tool is used to measure gear lash. 



FOR ELECTRICAL COMPONENTS 

1 . Electro Tester 
P/N YU-33260 -<J) 
This instrument is necessary for checking the 
ignition system components. 



2. Pocket Tester 

P/N YU-33263 - © or 

P/N YU-03112-(D 
This instrument is invaluable for checking the 
electrical system. 



1-10 



ADJ *gl 



CHAPTER 2. 
PERIODIC INSPECTIONS AND ADJUSTMENTS 

INTRODUCTION 2-1 

MAINTENANCE INTERVALSCHARTS 2-1 

PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM 2-1 

GENERAL MAINTENANCE/LUBRICATION 2-2 

ENGINE 2-4 

VALVE CLEARANCE ADJUSTMENT 2-4 

CRANKCASE VENTILATION SYSTEM INSPECTION 2-9 

FUEL LENE INSPECTION 2-9 

FUEL FILTER REPLACEMENT 2-10 

INTAKE MANIFOLD INSPECTION 2-10 

EXHAUSTSYSTEM INSPECTION 2-10 

CANISTER INSPECTION 2-11 

CARBURETOR SYNCHRONIZATION 2-11 

IDLING SPEED ADJUSTMENT 2-13 

THROTTLE CABLE ADJUSTMENT 2-13 

ENGINEOI L LEVEL INSPECTION 2-14 

ENGINE OIL REPLACEMENT 2-14 

COOLANT LEVEL INSPECTION 2-16 

COOLING SYSTEM INSPECTION 2-16 

COMPRESSION PRESSURE MEASUREMENT 2-17 

CHASSIS 2-18 

FINAL GEAR OIL LEVEL INSPECTION 2-18 

FINAL GEAR OIL REPLACEMENT 2-18 

AIR FILTER CLEANING 2-19 

BRAKE FLUID LEVEL INSPECTION 2-20 

FRONT AND REAR BRAKE PAD INSPECTION 2-21 

FRONT BRAKE ADJUSTMENT 2-22 

REAR BRAKE ADJUSTMENT 2-22 

CABLE INSPECTION AND LUBRICATION 2-23 

BRAKE AND CHANGE PEDALS/BRAKE AND 

CLUTCH LEVERS LUBRICATION 2-23 

CENTERSTAND AND SIDESTAND LUBRICATION 2-23 

SWINGARM LUBRICATION 2-23 

FRONT FORK OIL CHANGE 2-24 

FRONT FORK ADJUSTMENT 2-25 

REAR SHOCK ABSORBER ADJUSTMENT 2-26 

RECOMMENDED COMBINATIONS OF THE FRONT FORK 

AND THE REAR SHOCK ABSORBER SETTINGS 2-28 

STEERING HEAD INSPECTION 2-28 

STEERING HEAD ADJUSTMENT 2-28 

WHEEL BEARINGS CHECK 2-31 

TIRES CHECK 2-31 

WHEELS CHECK 2-34 




INSP 
ADJ 



<a 



ELECTRICAL , 2-34 

IGNITION TIMING CHECK 2-34 

BATTERY INSPECTION . , 2-35 

BRAKE LIGHT SWITCH ADJUSTMENT 2-37 

SPAR PLUG INSPECTION 2-37 

HEADLIGHT BULB REPLACEMENT 2-38 

HEADLIGHT BEAM ADJUSTMENT 2-39 

FUSE INSPECTION 2-39 



INSP 
ADJ 



<a 



INTRODUCTION/MAINTENANCE INTERVALS CHARTS 



PERIODIC INSPECTIONS AND ADJUSTMENTS 

INTRODUCTION 

This chapter includes all information necessary to perform recommended inspections and adjustments. 
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and 
a longer service life. The need for costly overhaul work will be greatly reduced. This information 
applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service 
technicians should be familiar with this entire chapter. 

MAINTENANCE INTERVALS CHARTS 

Proper periodic maintenance is important. Especially important are the maintenence services related 
to emissions control, These controls not only function to ensure cleaner air but are also vital to proper 
engine operation and maximum performance. In the following maintenance tables, the services related 
to emissions control are grouped separately. 

PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM 



No. 


Item 


Remarks 




1,000 km 

or 
1 month 
(600 mi) 


7,000 km 

or 
7 months 
(4,400 mi) 


* * o 

13,000 km 

or 
13 months 
(8,200 mi) 


19,000 km 

or 
19 months 
12,000mi) 


25,000 km 

or 
25 months 
(15,800 mi) 


**3 
31,000 krr 

or 
31 months 
(19,600 mi 


1* 


Check and adjust valve 

clearance when engine 
clearance , , 
is cold. 


Every 42,000 km (26,600 mi) 


2 


Spark plug 


Check condition. Adjust gap 
and clean. Replace at 
13,000 km (or 13 months) 
and thereafter every 12,000 
km (or 12 months). 




Replace 


o 


Replace 


o 


3* 


Crankcase 
ventilation 
system 


Check ventilation hose for 
cracks or damage. Replace 
if necessary. 














4* 


Fuel line 


Check fuel hose and vacuum 
pipe for cracks or damage. 
Replace if necessary. 




o 


o 


o 





o 


5 


Fuel filter 


Replace initial 31,000 km 
(19,600 mi) and thereafter 
every 30,000 km 
(19,000 mi). 












Replace 


6* 


Exhaust 
system 


Check for leakage. 
Retighten if necessary. 
Replace gasket (s) if 
necessarv. 














7" 


Carburetor 
synchro- 
nization 


Adjust synchronizationof 
carburetors. 


o 


o 


o 


o 


o 


o 


8* 


Idle speed 


Check and adjust engine 
idle speed. Adjust cable 
free paly. 




o 


o 


o 


o 


o 



NOTE: ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^_ 

For farther odometer reading, repeat the above maintenance at the period established; **1: Every 
6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi) and **3: Every 30,000 km (19,000 mi) 
intervals. 



2-1 



MAINTENANCE INTERVALS CHARTS 



INSP 
ADJ 



Ml 



GENERAL MAINTENANCE/LUBRICATION 





Item 


Remarks 


Type 


Initial 


Odometer reading 


o. 


000 km 
or 

month 
500 mi) 


**- 

',000 km 

or 
' months 
1,400 mi) 


""2 

3,000 km 

or 
3 months 
J,200 mi) 


I ""3 I 
9,000 km 125,000 km 1 

or or 
9 months 25 months 
2,000 fni)(15,800mi) 


31,000 km 
or 
1 months 
9,600 mi 


1 


Engine oil 


Narm-up engine 
oefore draining. 


See NOTE. 












o 




2 


Oil filter 


Replace. 


— 


o 




o 




o 




3* 


Air filter 


Slean with com- 
Dressedair. Re- 
Dlace if neces- 
iary . 


- 







o 


o 


o 





4* 


Cooling 
system 


Sheck hoses for 
:racks or 
damage, replace 
if necessary. 


- 




o 


o 





o 


o 


Replace coolant 
24 months. 


Ethylene 
glycol anti- 
■reeze 
:oolant 










Replace 




5" 


Brake 
system 


Adjust free play 
Replace pads if 
necessary. 


- 


o 


o 


o 


o 


o 


o 


6 


Final gear 
oil 


Check oil level 
and leakage. 
Replace every 
24,000 km or 
24 months. 


5AE80 
4PI 

"GL-4"hy- 
ooid gear 

Dil 


Replace 




Check 




o 




7 


Control 
and meter 
cable 


Apply chain 
lubethorought- 

ly. 


Yamaha 
chain and 
cable lube 
D rSAE 
1OW30 
motor oil 


o 


o 





o 


o 


o 


8 : 


Rear arm 

pivot 

bearing 


Check bearing 
assembly for 
looseness. 
Moderately 
repack every 
24,000 km 
(15,200 mi). 


Medium 

weight 

wheel 

bearing 

grease 










Replace 




9 


Brake/ 
Clutch lev 
pivot shaf 


Apply chain 
lube lightly. 


Yamaha 
chain and 
cable lube 
or SAE 
10W30 
motor oil 




o 


o 


o 





o 


10 


Brake ped 
and chang 
pedal shal 


Lubricate. 
Apply chain 
lube lightly. 


Yamaha 
chain and 
cable lube 
or SAE 
1OW30 
motor oil 




o 


o 


o 


o 


o 


11 


Center/Sid< 

stand 

pivots 


Check 

operation and 
lubricate. 
Apply chain 
lube lightly. 


Yamaha 
chain and 
cable lube 
or SAE 
1OW30 
motor oil 




o 


o 


o 


o 


o 


12 


Front 
fork oil 


Check operatio 
and leakage. 


- 




o 


o 


o 


o 


o 























2-2 



INSP 
AD J 



<& 



MAINTENANCE INTERVALS CHARTS 



. Steering 
3*. bearings 



Remarks 



14* 



Wheel 
bearinqs 



Check bearings 
assembly for 
looseness. 
Moderately 
repack every 
24,000 km 
(15,200 mi). 



Check bearings 
for smooth 
rotation. 



15* 



16* 



Battery 



Sidestand 
switch 



Check specific 
gravity and 
breather pipe 
for proper 
operation. 



Check and clean 
or replace if 



* It is recommend 
NOTE: 



Type 



Medium 

weight 

wheel 

bearing 

grease 



Initial 



1,000 km 

or 
1 month 
(600 mi) 



Odometer reading 



7,000 km 

or 

7 months 



13,000 km 
or 



19,000 km 
or 



13 months 19 months 



(4,400 mi), (S,200 mi) {12,QQQ mi) 



25,000 km 31,000 krr 

or or 

25 months 31 months 
(15,800 mi) (19,600 mi 



Repack 



• For farther odometer reading, repeat the above maintenance at the period established; **1: Every 
6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi), and **3: Every 24,000 km (15,200 mi) 
intervals. 

*Brake fluid replacement (brake and clutch): 

1) When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally 
check the brake fluid level and add the fluid as required. 

2) On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two 
years. 

3) Replacethe brake (clutch) hoses every four years, or it cracked or damaged. 

• Engine oil: 



30 



40 



50 60 F 



Yamalube 4-cycle Oil or 

SAE 20W40 Type SE Motor Oil 

SAE 1OW30Type SE Motor Oil 



10 15°C 



~~A i 






^ 



2-3 



VALVE CLEARANCE ADJUSTMENT 



INSP 
ADJ 



<fi 




ENGINE 

VALVE CLEARANCE ADJUSTMENT 
Removal 
1. Remove: 

•Top cover (D 

• Covers (left and right) (2) 




2. Remove: 

.Electrical components board ® 

3. Disconnect: 

• All electrical component leads 



4. Remove: 

• Side covers (radiator)® 

• Bolts (radiator) 



NOTE: 

It is not necessary to remove the radiator 
completely from the motorcycle. 



5. Disconnect: 

• Spark plug caps 

6. Remove: 

• Air baffle plate (rear)© 



7. Remove: 

• Cylinder head covers 



NOTE: 

Be sure you do not lose the oil plugs® on the 
camshaft caps. 



2-4 



1NSP 
ADJ 



<a 



VALVE CLEARANCE ADJUSTMENT 




'I P f '"^1 



8. Remove: 

*Crankcase cover plate (T) 
*Special washer (|) 
•Timing plug® 

NOTE: 



Check for clog of oil passage (?) in the bolt. 
If any, clean the oil passage. 



Inspection and Adjustment 
1. Measure: 
*Valve clearance 

NOTE: 

Be sure piston is at Top Dead Center (TDC) 
when measuring clearance. 

By the following measurement steps. 



Valve clearance measurementsteps: 
Turn the crankshaft counterclockwise with a 
32 mm (1.26 in) socket wrench (T) . 



NOTE: 

Valve clearance must be measured when the 
engine is cool to the touch. 



*Align the "Tj •■ mark (forthe No. 1 cylinder) 
on the flywheel with the stationary pointer 
(2) on the crankcase cover. When the "T, " 
mark is aligned with the stationary pointer 
(2) ,the piston is at top dead center TDC. 

*Note marks on flywheel to obtain correct 
valve clearance measurements. 

(D TDC for No. 1 cylinder 
(4) TDC for No. 2 cylinder 

• Measure the valve clearance using a Feeler 
Gauge© . 

• Record the measured amount ifthe clearance 
is incorrect. 



m 



Intake Valve (cold): 
0.11 _ 0.15 mm 
(0.004 " 0.006 in) 

ExhaustValve (cold): 
0.26- 0.30 mm) 
(0.010- 0.012 in) 



"> 



2-5 



v_ 



VALVE CLEARANCE ADJUSTMENT 



INSP 
ADJ 



a 







A 



TD 




C 


180° 


360' 


540 1 




720' 




900 e 




B 


No. 1 






















No. 2 












No. 3 


l 






No. 4 




I 


■■^■■B 










180' +70° 






110° 




110 









Y77ZW77777777 



SL 



i — i- — ® 



<&— £ 



-t 



aHS 



(D 




[a1 Crankshaft degree 
| | Cylinder 

*Measure the valve clearance, in sequence, for 
Nor. 3, 4, and No. 2 cylinders. 
Out of specification ->• Adjust clearance. 

(T) Front 




2. Adjust: 

*Valve clearance 
By the following adjustment steps. 



Valve clearance adjustment steps: 

• Position the valve lifter slots (intake and 
exhaust side) opposite each other. 

install the Tappet Adjusting Tool (T) (YM- 
33961 ) onto the camshaft © . 



"Turn the crankshaft until the lobe of the 
tool (£) depresses the valve lifters (D . 



(?) Cylinder head 
(5) Pad 



2-6 



INSP 
ADJ 



Ml 



VALVE CLEARANCE ADJUSTMENT 




» Remove the pads (5) from the lifters. Use a 
small screwdriver and a magnetic rod for 
removal. 

• Note pad numbers. 

• Select the proper valve adjusting pad from 
the chart below: 



Pad range 



Mo. 200- 
No. 320 



200 mm 
(0.079 in) 

320 mm 
(0.130 in) 



Pad Availability : 
25 increments 



Pads stepped in 0.05 
mm (0.002 in) incre- 
ments 



Hundredths digit 



0or2 



Rounded valve 







(NOT ROUNDED OFF 
10 



2-7 



VALVE CLEARANCE ADJUSTMENT 




INTAKE 



□ 

MEASURED 
CLEARANCE 


E INSTALLED PAD NUMBER 


200 


205 


210 


215 


220 [ 225 


230 | 235 | 240 | 246 


250 


255 


260 1 265 j 270 ] 275 [ 280 285 1 290| 295 


300 


?;n 


310 


315 


32C 


0.00- 


-0.05 






200 


205 


2101215 


220122512301235 


240 


245 


250125512601265 1270127512801285 


290 


295 


300 


305 


31C 


006 


0.10 




200 




210 


215 




225 


:> ic 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


3 " E 


0.11- 


-0.15 




















































0.16- 


-0.20 


205 


210 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 




0.21- 


-0.25 


210 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.26- 


-0.30 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


TiO 


295 


300 


305 


310 


315 


320 






0.31- 


35 


220 


225 


230 


235 


240 


245 


250 


255 


260 


26S 


270 


275 


2 B0 


2B5 


290 


295 


300 


305 


310 


315 


320 






36 


0.40 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.41 


-0 45 


230 


235 


240 


245 


250 


255 


260 


265 


270 


2 75 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0*6 


50 


235 


240 


245 


250 


?55 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.61 - 


55 


240 


245 


250 


255 


260 


265 


; 70 


275 


280 


28B 


290 


295 


300 


305 


310 


315 


320 






66 


-0.60 


24S 


250 


255 


260 


265 


270 


27b 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.61 


65 


250 


255 


26:.! 


265 


270 


275 


280 


285 


290 


295 


300 


306 


310 


315 


320 






66 


-0.70 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


3 1 


315 


3 20 






0.71- 


0.76 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.76- 


0.80 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


316 


S20 






81 


85 


270 


275 


280 


235 


290 


295 


300 


305 


310 


3 1 5 


320 






86 


-0 90 


2 75. 


280 


285 


290 


295 


300 


305 


310 


315 


320 




VALVt ULtAKAiNiot ^coia;: 


0.91 -0.95 


2 BO 


265 


290 


295 


300 


305 


310 


315 


320 




0.11 0.15 mm (0.004" 0.006 in) 


096 


-1.00 


285 


290 


295 


300 


306 


310 


315 


320 




Example: Installed is 250 


1.10 


-1.05 


290 


295 


300 


305 


310 


315 


320 




Measured clearance is 0.32 mm (0.013 in) 


1 06 


- 1 10 


295 


300 


305 


3 1 


315 


320 




ReDlace250 Dad with 270 Dad 


111 - 


-1 15 


300 


305 


310 


315 


320 






1 16 


-1 20 


305 


310 


315 


320 






1.21 


1 .25 


310 


315 


320 






1 26 


1 30 


315 


32'J 




raa ino. zoo -z.oo mm ^u. iuu in; 


1.31 


1 35 


320 
























Always 


install pad with 


nurr 


ber down. 









EXHAUST 



® 

MEASURED 
CLEARANCE 


in} I mo I hlucu mis munnotn 


200 


205 


210 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


306 


310 


315 


32 


00-0.05 








300 


?'jb 


210 


215 


220 


225 


230 


235 


240 


245 


?50 


?56 


260 


265 


270 


275 


280 


285 


290 


295 


300 


30 


0.06 — 0.10 






200 


206 


210 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


31 


11-0.15 




200 


205 


210 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


2B0 


285 


290 


295 


l22°_ 


305 


310 


31 


16-O.20 




















































0.21 - 0.26 


205 


210 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 




0.26- O 30 


210 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.31 —0.36 


215 


220 


225 


230 


235 


240 


245 


250 


255 


260 


265 


2 70 


2 75 


280 


2B5 


290 


295 


300 


305 


310 


315 


320 






36—0 40 


2 JO 


225 


230 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.41—0 46 


325 


230 


235 


240 


245 


250 


255 


260 


265 


270 


2 75 


280 


285 


290 


295 


300 


305 


310 


315 


320 






46-050 


2 30 


235 


240 


245 


250 


255 


260 


265 


2 70 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.51—0.56 


235 


240 


245 


250 


255 


260 


265 


270 


275 


280 


28S 


290 


295 


300 


305 


310 


315 


320 






56-080 


240 


245 


250 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






0.61 -0 65 


245 


250 


255 


260 


265 


270 


275 


2 B0 


2B5 


290 


295 


300 


305 


310 


315 


320 






0.66-0.70 


250 


255 


260 


265 


2 70 


275 


280 


285 


290 


295 


300 


305 


310 


31b 


320 






0.71—0.75 


255 


260 


265 


270 


275 


280 


285 


290 


295 


300 


305 


310 




320 






0.76 — O.BO 


260 


265 


270 


275 


280 


265 


290 


295 


300 


305 


310 


315 


320 






0.81—0 85 


265 


270 


275 


2B0 


?H5 


290 


295 


300 


306 


310 


315 


320 






86-0.90 


270 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






91-0.95 


275 


280 


285 


290 


295 


300 


305 


310 


315 


320 






96-1.00 


280 


285 


290 


295 


300 


305 


310 


315 


320 






1.10-1.05 


2B5 


290 


295 




JO! 


310 


315 


320 






1.06 — 1.10 


290 


295 


300 


305 


310 


3151320: 


L 


Measured clearance is 0.32 mm (0.013 in) 


1.11—1.15 


295 


300 


305 


310 


315 


320] 


. 


ReDlace250 Dad with 265 Dad 


1.16 — 1.20 


300 


305 


310 


315 


320 






1.21—1.25 


305 


310 


315 


320 






1.26 — 1.30 


310 


315 


320 






1.31—1.35 


315 


320 




i-'aa ino. zoo -z.oo mm iu.'iuu in; 


1.36—1.40 


320 






















Alw 


ays 


inst 


all p 


adw 


ith 


ium 


ber 


aow 


1. 









2-8 



!NSP |0I 
ADJ *MI 



CRANKCASE VENTILATION SYSTEM INSPECTION/ 
FUEL LINE INSPECT ION 

Assembly 

When installing the top cover, reverse the 
removal procedure. Note the following points. 
1. Install: 
• Cylinder head covers 




NOTE: 

• Be sure all cam caps are coverd with oil plug 

*Arrow mark (§) on the cover should face 

toward the exhaust side. 
Inspect the head cover gasket and replace it if 

damaged. 

2. Tighten: 

*Bolts (cylinder head cover) 




Bolts (Cylinder Head Cover): 
10 Nm (1.0m-kg, 7.2 ft-lb) 



3. Tighten: 

• Bolts (radiator) 



^j B 1 



Bolts (Radiator): 

Nm (0.7 m-kg, 5.1 ft-lb) 




CRANKCASE VENTILATION SYSTEM 
INSPECTION 
1. Inspect: 
Crankcase ventilation hose(f) 
Cracks/Damage -> Replace. 



FUEL LINE INSPECTION 
1. Inspect: 
• Fuel hoses 
*Vacuum lines 
Cracks/Damage -> Replace. 



2-9 



) 



FUEL FILTER REPLACEMENT/ 

INTAKE MANIFOLD INSPECTION/ 

EXHAUST SYSTEM INSPECTION 



INSP 



ADJ 



m 




FUEL FILTER REPLACEMENT 

1. Remove: 
•Seat 

• Bracket 

• Fuel filter® 

2. Inspect: 

• Fuel filter 
Dirty/Damage^- Replace. 

3. Install: 

.Components in above list (step "1 ") 



INTAKE MANIFOLD INSPECTION 

1 . Tighten : 

• Carburetor clamps 

• Carburetor joint bolts 
Carburetorjoint nuts 

2. Inspect: 

• Carburetorjoint 

• Gaskets 
Cracks/Damage -> Replace. 



EXHAUST SYSTEM INSPECTION 

1. Inpsect: 

• Exhaust pipe 

• Muffler clamp gasket(s) 
Damage ->■ Replace. 

2. Tighten: 

• Exhaust pipe bolts 

• Muffler bolts 



fl 



Exhaust Pipe Joint: 

7Nm (0.7m-kg, 5.1 ft-lb) 
Exhaust Pipe Flange: 

20Nm(2.0m.kg, 14 ft-lb) 
Muffler Clamp: 

20Nm(2.0m-kg, 14 ft-lb) 



2-10 



IS 



INSP 
ADJ 



CANISTER INSPECTION/CARBURETOR SYNCWRONJZATION 



(f) 






>>® 




S/ 


<£ 





CANISTER INSPECTION (FOR CALIFORNIA 
ONLY) 
1. Inspect: 

• Hose connection 

Poor condition -»■ Correct. 

• Hoses 

• Canister 
Cracks/Damage -> Replace. 
Clogs -»■ Clean. 



(J) To carburetor 
(f) From fuel tank 
(|) Canister 
(4) To atmosphere 

CARBURETOR SYNCHRONIZATION 

(D OPEN 
(2) CLOSE 



•"""> 






© ® 




■^ 



2-11 



CARBURETOR SYNCHRONIZATION 



INSP 
ADJ 



ai 



<~ 



-~ 



<* 




NOTE: 

Valve clearance must be set properly before 
synchronizing the carburetors. 

1. Remove: 
Carburetor joint covers (left and right)® 

• Vacuum plugs (left and right)© 

• Vacuum hose (3) 



2. Attach: 

• Vacuum Gauged) (YU-08030) 
To the vacuum plugs. 

3. Start the engine and let itwarm up. 



4. Adjust: 
•Idle speed 
Out of specification -> 
Turn the throttle stop screw (T) to adjust. 



m 



Idle Speed: 

1,000+ 50r/mir 



Carburetor synchronization adjustment steps: 
.Synchronize carburetor No. 1 to carburetor 
No. 2 by turning synchronizing screw "A" 
until both gauges read the same. 
• Rev the engine for a fraction of a second, 
two or three times, and check the synchro- 
nization again. 



INSP 


<st 


ELIG SPEED ADJUSTMENT/ 


ADJ 


THROTTLE CABLE ADJUSTMENT 




Vacuum Pressure at Idle Speed: 

22.61 kPa (170 mm Hg, 6.69 in Hg) 

Vacuum Synchronous Difference: 
2.66 kPa (30 mm Hg, 0.79 in Hg) 



*Repeat the above steps to synchronize 
carburetor No. 3 to carburetor No. 4 by 
turning synchronizing screw "B " until 
both gauges read the sam e . 

• Repeat the same steps to synchronize No. 4 
carburetor to No. 2 carburetor, then turn 
synchronizing screw "C " until both gauges 
read the sam e . 




IDLE SPEED ADJUSTMENT 
1. Adjust 
• Hie speed 
W arm up the engine and turn the throttle 
stop screw (Jj| to adjjst. 



A 



Idle Speed: 

1,000+ 50r/min 



THROTTLE 
NOTE : 



CABLE ADJUSTMENT 



Before adjusting the throttle cable free play, the 
engine idling speed should be adjusted. 



1. Check: 

Throttle cable free paly @| 
Out of specification -M Adjust. 



m 



Throttle Cable Free Play (a) : 
4- 7 mm {0.16- 0.28 in) 



2. Adjust: 

Throttle cable free play 
By the following adjustment steps, 



Throttle 


cable adjustm en 


t steps : 






• Loosen 


the locknut r V) 








•Turnl th 


e adjuster ($\ 


clockw ise 


or 


countEr- 


clockw 


ise until proper 


free play 


is 


a trained . 


Tighten 


the locknut, 









2-13 



ENGINE 01 LEVEL INSPECTION/ 


INSP 


<a 


ENGIE OIL REPLACEMENT 


ADJ 




ENGIE OIL LEVEL ISPECTDN 
1. lispect : 
• il level 
Oil level low ^ Add sufficient oil. 
By the following inspection steps. 



Engine oil level visual inspection sbeps: 
•Placd the m otorcycle on its centerstand and 
waim up the engine for several minutes. 



NOTE: 

Position motorcycle straight up when check- 
ing oil level, a slight tilt to the side can 

produce false readings. 



*Stop the engine and visually check the oil 
level through the level window (T) . 



®» 



axim um 



M in dm um 



ENGIE OIL REPLACEMENT 

Engine O ilReplacem ent (W ithoutO ilFilter) 

1. W arm up the engine for several m inutes, 
then place a receptacle under the engine. 

2 . Rem ove : 

*0 il filler cap 



r^ 




3 . R em ove : 

*Drain plug (J) 
Drain the engine oil 
4. Tighten: 

• DraidpiigCD 



m 



Drain Plug: 

43 Nm (4 3 m -kg, 31 



5. Fill: 

*C rankcase 



*0 



Recommended Oil: 

At 5°C (40° F) or Higher® : 
Yamalube 4-cycle Oil or 
SAE 20W40 Type SE Motor Oil 

At 15° C (60° F) or Lower © : 

SAE Type SE M otor il 

Periodic Oil Change: 

3 5 L (3 .1 11 p qt, 3 .7 US qt) 



2-14 



INSP 
ADJ 



M 



ENGINE OIL REPLACEMENT 



CAUT10N: 





Do not albw foreign material to enter the crank- 
case. 

6 . Install: 

• Filled cap 

7 . Inspect: 

• Oil teaks 
*0 a level 

Engine O ilReplacem ent (K it±i O ilFilter) 
1 . W ami up the eng±ie and place a isceptacle 
under the eng±ie . 

2 . R em ove : 

• Oil 3ter cap 

• Drain piig 

D rail the enghe oiL 

3 . R em ove : 

• Oil filter cover ® 

4 . JistalL- 

• D rah plig 



ffl 



Drain Plug: 

43 Nm (4.3 mkg, 31 ft-lb) 



• Oil filer hew) 

• -rhg (new ) 

• Oil filter cover 
NOTE: 



Be suie the -rhg (J) is positbned proper^. 




5. Tijhten: 

*Bot (oil filter) 



a 



Bolt (Oil Filter): 

32 Nm (3.2 mkg, 23 ft-lb) 



6. FUL 

@ Crankcase 



•ft 



Recom m ended il: 

At 5" C (40" F) orHdgher{T)|] 
Yamalube 4-cycle Oil or 
SAE 20W 40 Type SE Motor O il 
Atl5°C (60" F) or Lower© : 

SAE 10W 30 Type SE M otor O il 
With Oil Filter Replacement: 
3 .8 L (3 3 111 p qt, 4 .0 US qt) 



CAOTION: 



Do not allow foreign material to enter the 

crankcase. 



2-15 



COOLANT LEVEL INSPECTION/COOLING SYSTEM INSPECTION 



INSP 
ADJ 



Ml 



7. Install: 

• Oil filter cap 

8. Inspect: 

• Oil leaks 

• Oil level 




COOLANT LEVEL INSPECTION 

1. Remove: 

• Top cover 

2. Inspect: 

*Coolant level (reservoir tank) 
Level low^ Add tapwater (softwater). 
Change the Coolant every two years. 
Refer to Chapter 4 "COOLING SYSTEM" 
for more detail. 

® "FULL" level 
(2) "LOW" level 



WARNING: 



Do not remove the radiator cap when the 
engine is hot. 

Hard water or salt water is harmful to the engine 
parts; use boiled or distilled water if you can't 
get soft water. 



jft 



Total Amount: 

3.05L (2.69lmpqt, 3.22USqt) 

Reservoir Tank Capacity: 

0.30L (0.26lmpqt, 0.32 USqt) 

From LOW to FULL Level: 

0.20 L (0.18 Impqt, 0.21 USqt) 



COOLING SYSTEM INSPECTION 
1. Inspect: 
• Hoses 
Cranks/Damage^ Replace. 



2-16 



INSP 
ADJ 



M 



COMPRESSION PRESSURE MEASUREMENT 



COMPRESSION PRESSURE MEASUREMENT 




NOTE: 

Insufficient compression pressure will result in 
performance loss. 

1. Measure: 

• Valve clearance 
Out of specification-* Adjust. 

2. Warm up the engine. 

3. Remove: 
•Spark plugs 

4. Measure: 
•Compression pressure 

By the following measurement steps. 



Compression pressure measurement steps: 

• Install the Compression Gaugel © (YU- 
33223) using an adapter. 

• Crank over the engine with the electric 
starter (be sure the battery is fully charged) 
with the throttle wide open until the com- 
pression reading on the gauge stabilizes. 

• Check redings with specified levels (See 
chart) 



Compression Pressure (at sea level): 
Standard: 

980kPa (10kg/cm 2 , 142 psi) 
Minimum: 

882 kPa (9 kg/cm 2 , 128 psi) 
Maximum: 

1.176.8 kPa (12 kg/cm 2 , 171 psi) 



WARNING; 



When cranking the engine, ground all of the 
spark plug leads to prevent sparking. 



• Repeat the previous steps for the other 
cylinders. 

• If pressure falls bellow the minimum level: 

1) Squirt a few drops of oil into the affected 
cylinder. 

2) Measure the compression again. 



Compression Pressure 
(with oil introduced into cylinder) 



Reading 



Higher than without 
oil 



Diagnosis 



Worn or damaged 

pistons 



"■> 



~> 



> 



2-17 



FINAL GEAR OIL LEVEL INSPECTION 
FINALGEAR OIL REPLACEMENT 



INSP 



ADJ 



a 



Same as without oil 



Above maximum level 



Defective ring(s), 
valves, cylinder head 
gasket or piston is 
possible. 



Inspect cylinder head, 
valve surfaces, or 
piston crown for 
carbon deposits. 



NOTE: 

The difference between the highest and 
lowest cylinder compression readings must 
not vary more than the specified value. 



Difference Between Each Cylinder: 
Lessthan 98 kPa (1 kg/cm 2 , 14psi) 




CHASSIS 

FINAL GEAR OIL LEVEL INSPECTION 
1. Inspect: 
• Final gear oil level 
Oil level low^ Add sufficient oil. 
By the following inspection steps. 



Final gear oil level visual inspection steps: 

• Position the motorcycle on a level area and 
place on its centerstand. 

• Remove the oil filler cap (T) . 

• Visually check the oil level. Correct oil 
level (2) should be at the brim of the hole. 

• If the oil level is low, add sufficient oil. 
•Tighten the oil filler cap to specification. 



fi 



Oil Filler Cap (Final Gear): 
23 Nm (2.3m-kg, 17ft-lb) 




FINAL GEAR OIL REPLACEMENT 

1. Place a receptacle under the final gear case. 

2. Remove: 

• Oil filler cap 

• Drain plug (D 
Drain the oil. 



2-18 



!NSP 10* 
ADJ %A 



AIR FILTER CLEANING 



3. Install: 
• Drain plug 



fj 



Drain Plug (Final Gear): 
23 Nm (2.3m-kg, 17ft-lb) 



4. Fill: 

• Final gear case 



<o 



Oil Capacity: 

0.2 L (0.18 Impqt, 0.21 US qt) 
Final Gear Oil: 
SAE 80 API "GL-4" Hypoid 
Gear Oil 
If desired, an SAE 80W90 Hypoid gear oil 
may be used for all conditions. 



WARMING: 



Do not allow the gear oil to contact the tire or 
wheel. 



5. Install: 
• Oil filler cap 



fj 



Oil Filler Cap (Final Gear): 
23 Nm (2.3m -kg, 17fMb) 




AIR FILTER CLEANING 
1. Remove: 
• Top cover 



2. Remove: 

• Air filter case cover 

• Air filter element 

CAUTION; 



The engine should never be run without the air 
filter element installed; excessive piston and/or 
cylinderwear may result. 



2-19 



BRAKE FLUID LEVEL INSPECTION 



INSP 
AD J 



<SL 




3. Eliminate: 
*Dust 

Use the compressed air. 

Blow out dust in the element from the 

outer surface. 

4. Inspect: 

• Element 
Damage^ Replace. 

5. Install: 

• Element 

• Air filter case cover 

• Top cover 




BRAKE FLUID LEVEL INSPECTION 

Brake Inspection 
1. Inspect: 
• Brake fluid level (brake master cylinder) 
Level low-* Replenish flu id. 



*Q 



Brake Fluid: 

DOT #3 



(T) Lower level 
NOTE: 



Be sure that: 

• Spilled fluid is cleaned up immediately to pre- 
vent painted surfaces or plastic parts from 
erodina. 



WARNING: 



• Use only the designated quality brake fluid, 
otherwise poor brake performance will result. 

*Water does not enter the master cylinder when 
refilling, otherwise poor brake performance. 



2-20 



INSP i£| 
AD J \SSi 



FRONT AND REAR BRAKE PAD INSPECTION 



Clutch Inspection 

This motorcycle has a hydraulic clutch. There 
are no adjustments to perform, but the clutch 
system must be inspected periodically for fluid 
level and leakage. 

1. Inspect: 
• Brake fluid level (clutch master cylinder) 
Level low -> Replenishfluid. 




*fr 



Brake Fluid: 
DOT ^3 



(T) Lower level 

NOTE: 

Be sure that: 

• Use only the designated quality brakefluid. 

• Water does not enter the master cylinder when 
refilling. 

.Spilled fluid is cleaned up immediately to 
prevent painted surfaces or plastic parts from 
eroding. 




FRONT AND REAR BRAKE PAD 
INSPECTION 

1. Activate the brake lever or brake pedal. 

2. Inspect: 

•Wear indicator (7) 
Indicator almost contacts disc -+ Replace 
pads. 
Refer to "Chapter 5 CHASSIS" section. 



~> 



2-21 



FRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENT 



INSP 
ADJ 



m 





FRONT BRAKE ADJUSTMENT 

1. Loosen: 

• Lockunt © 

2. Adjust: 
*Free play (a) 

Turn the adjuster (2) until the free play (a) 
is within the specified limits. 



m 



Free play (a) : 

2~ 5 mm (0.08 ~ 0.20 in) 



CAUTION: 



Proper lever free play is essential to avoid 
excessive brake drag. 



WARNING: 



A soft or spongy feeling in the brake lever 
can indicate the presence of air in the brake 
system. This air must be removed by bleeding 
the brake system before the motorcycle is 
operated. Air in the system will cause greatly 
diminished braking capability and can result in 
loss of control and an accident. Inspect and 
bleed the system if necessary. 

3. Tighten: 
• Locknut 



REAR BRAKE ADJUSTMENT 

1. Loosen: 

• Locknut (j) 

2. Adjust: 

*Brake pedal height (a) 
Turn the adjuster (2) until the brake 
pedal position is at the specified height. 




Brake Pedal Height(D : 
20 mm (0.8 in) 
Below the Top of the Footrest 



WARNING: 



After adjusting the brake pedal height, visually 
check the adjuster end through the hole (3) of 
the joint holder. The adjuster end must appear 
within this hole. 



2-22 



INSP 
ADJ 



<& 



CABLE INSPECTIONAND LUBRICATION/BRAKE AND CHANGE 
PEDALS/BRAKE AND CLUTCH LEVERS LUBRICATION/CENTER- 
STAND AND SIDESTAND LUBRICATION/SWINGARM LUBRICATION 

CABLE INSPECTIONAND LUBRICATION 



Cable inspection and lubrication steps: 
*Remove the screws that secure throttle 
housing to handlebar. 

• Hold cable end high and apply several drops 
of lubricant to cable. 

•Coas metal surface of disassembled throttle 
twist grip with suitable all-purpose grease to 
minimize friction. 

• Check for damage to cable insulation. 
Replace any corroded or obstructed cables. 

*Lubricate any cables that do not operate 
smoothly. 



ra 



Yamaha Chain and Cable Lube or 
SAE 10W30 Motor Oil 



BRAKE AND CHANGE PEDALS/BRAKE 
AND CLUTCH LEVERS LUBRICATION 
Lubricate pivoting parts of each lever and pedal. 



S 



Yamaha Chain and Cable Lube or 
SAE 10W30 Motor Oil 



CENTERSTANDAND SIDESTAND 

LUBRICATION 

Lubricate the centerstand and sidestand at their 

pivot points. 



S 



Ymaha Chain and Cable Lube or 
SAE 10W30 Motor Oil 



SWINGARM LUBRICATION 
Lubricate the swingarm bearing. 



""> 



S 



Medium Weight Wheel 
Bearing Grease 



2-23 



FRONT FORK ADJUSTMENT 



INSP 
ADJ 



m 



FRONT FORK OIL CHANGE 



/- 



WARNING: 



• Fork oil leakage can cause loss of stability 
and safe handling. Have any problem corrected 
beforeoperatingthe motorcycle. 

• Securely support the motorcycle so there is 
no danger of it falling over. 



^ 




1. Elevate the front wheel by placing a suitable 
stand underthe engine. 

2. Remove: 

• Air valve cap (left) 

• Fork caps(T) 

NOTE: 

Keep the valve open by pressing it for several 
seconds so that the air can be let out of the 
innertube. 

3. Loosen: 

• Pinch bolts (steeringcrown) © 

4. Remove: 

• Cap bolts© 

Use the Front Fork Cap Socket (f) (YM- 
01104). 
'Collars 

5. Place a receptacles underthe drain screws. 

6. Remove: 

• Drain screws (T) 
Drain the fork oil. 



WARNING: 



Do not allow any oil to contact the disc brake 
components. If oil is discovered, be sure to 
remove it, otherwise diminished braking capa- 
city and damage to the rubber components of 
the brake assembly will occur. 

7. Inspect: 

• O-rings (cap bolt) (T) 

• Gaskets (drain screw) 
Wear/Damage -> Replace. 



2-24 



s 



INSP 
ADJ 



FRONT FORK ADJUSTMENT 



8. Install: 

• Drain screws 

•Collars 

9. Fill: 

• Front forks 



*ft 



Each Fork: 
451 cm 3 (15.9 Imp oz. 15.3 US oz] 
Yamaha Fork Oil 1 Owt orEquivalent 

filling, pump the forks slowly up and 



After 

down to distribute the oil 



10. Tighten: 

• Cap bolts 

Use the Front Fork Cap Socket (YM- 
01104). 

• Pinch bolts (steering crown) 



ffl 



Cap Bolt: 

23Nrn (2.3 m-kg, 17fMb) 
Pinch Bolts (Steering Crown): 

20Nrn (2.0 m-kg, 14fMb) 



11. Adjust: 

• Front fork air pressure 
Refer to "FRONT FORK ADJUSTMENT" 
section. 



FRONT FORK ADJUSTMENT 

1. Elevate the front wheel by placing a suitable 
stand under the engine. 

NOTE: 

When checking and adjusting the air pressure, 
there should be no weight on the front end of 
the motorcycle. 

2. Adjust: 

• Air pressure 

NOTE: 

The air pressure of the front forks can be 
adjusted to suit rider's preference, weight, and 
the course condition. 



2-25 






REAR SHOCK ABSORBER ADJUSTMENT 



INSP iQfc 

adj *ql 




By the following adjustment steps. 



Air pressure adjustment steps: 

• Remove the valve cap. 

• Using the air check gauge (f) , check and 
adjust the air pressure. 



Stiffer 



Softer - 



Increase the air pressure. 

(Use an air pump or pressurized air 

supply.) 

Decrease the air pressure. 

(Release the air by pushing the 

valve.) 



Standard Air Pressure: 

39.2 kPa (0.4 kg/cm 2 , 5.7 psi) 
Maximum Air Pressure: 

98.1 kPa (1.0 kg/cm 2 , 14.2 psi) 



CAUTION: 



Never exceed the maximum pressure, or oil 
seal damage may occur. 



• Install the valve cap securely. 



REAR SHOCK ABSORBER ADJUSTMENT 
1. Adjust: 
•Spring preload 
*Damping 

NOTE: 

The spring preload and damping of the rear 
shock absorbers can be adjusted to suit rider's 
preference, weight, and the course condition. 



WARNING: 



Always adjust rear shock absorber preload and 
damping to the same setting. Uneven adjustment 
can cause poor handling and loss of stability. 



2-26 






!NSP |0l 
AD J l*g| 



REAR SHOCK ABSORBER ADJUSTMENT 




By the following adjustment steps. 



Spring preload adjustment steps: 
*Using the screwdriver, adjust the spring 
preload. 



Stiffer (a) -> Increase the spring preload. 

(Turn the spring seat (T) clock- 
wise.) 

Softer (§) -* Decrease the spring preload. 

(Turn the spring seat (?) counter- 
clockwise.) 



El Position: 5 (Maximum) 
4 
3 
2 
1 (Minimum/Standard) 



Standard Position (Minimum Position): 

1 
Maximum Position: 



CAUTIQ&: 



Never attempt to turn the spring seat beyond 
the maximum or minimum setting. 




Damping adjustment steps: 
• Adjust the damping with the damping 
adjuster (D . 



Stiffer (a) • 
Softer© ■ 



Increase the damping. 
(Turn the adjuster(T) clockwise.) 
Decrease bhe damping 
(Turn the adjuster (T) counter- 
clockwise.) 



Standard Position (Minimum Position): 

1 
Maximum Position: 

4 



MFriON: 



Never attempt to turn the adjuster beyond 
the maximum or minimum setting. 



2-27 



RECOMMENDED COMBINATIONS OF THE FRONT 

FORK AND THE REAR SHOCK ABSORBER SETTINGS/ 

STEERING HEAD INSPECTION/STEERING HEAD ADJUSTMENT 






INSP 



ADJ 



RECOMMENDED COMBINATIONS OF THE FRONT FORK AND THE REAR SHOCK ABSORBER 
SETTINGS 

Use this table as guidance to meet specific riding conditions and motorcycle load. 



A Front fork 


C 


Rear shock absorber 


F 


Loading condition 


B 

Air pressure 


D 

Spring seat 


El 

Damping 
adjuster 


G 

Solo rider 


H 

With 
passenger 


I 

With accessory 
equipments 


J 

With accessory 

equipments 

and passenger 


39.2 - 58.8 kPa 
(0.4- 0.6 kg/cm 2 , 
5.7 ~ 8.5 psi) 


1or2 


1 or 2 


O 








39.2- 98.1 kPa 
(0.4- 1.0 kg/cm 2 , 
5.7- 14.2 psi) 


3- 5 


2- 4 




O 


O 




39.2 - 98.1 kPa 
(0.4- 1.0 kg/cm 2 , 
5.7- 14.2 psi) 


5 


4 








O 




STEERING HEAD INSPECTION 



WARNING: 



Securely support the motorcycle so there is 
no danaer of it fallina over. 

1. Place the motorcycle on its centerstand, 
then elevate the front wheel. 

2. Check: 

• Steering assembly bearings 
Grasp the bottom of the forks and gently 
rock the fork assembly back and forth. 
Looseness -> Adjust steering head. 



STEERING HEAD ADJUSTMENT 



WARNING: 



Securely support the motorcycle so there is no 
danger of it falling over. 

1. Elevate the front wheel by placing a suitable 
stand under the engine. 



2-28 



JNSP 
ADJ 



M 



STEERING HEAD ADJUSTMENT 




2. Remove: 

• Headlight lens unit (j) 

3. Disconnect: 

• All leads (inthe headlight body) 



4. Remove: 

• Bolt (headlight body bracket)® 

# Emblem© 



5. Remove: 

*Flasher light bracket assembly 



6. Remove: 

• Handlebar holder assembly (T) 



7. Loosen: 

*Pinch bolts (steering crown )(T) 

8. Remove: 

• Nut (steering stem) (2) 
*Steering crown (3) 



2-29 



STEERING HEADADJUSTMENT 



INSP 
ADJ 



51 




9. Remove: 

• Lock washer (ring nut) (J) 

• Ring nut (upper)© 
•Washer © 

• Ring nut (lower)® 



WARNING: 



Support the under bracket so that it may not 
fall down. 

10. Tighten: 

• Ring nuts (lower and upper) 
By the following tightening steps. 



Ring nuts tightening steps: 

• Install the ring nut (lower)© 

NOTE: 



The tapered side of ring nut must face down- 
ward. 



•Tighten the ring nut © using the Ring Nut 
Wrench (YU-33975). 



a 



Ring Nut 6 (InitialTightening): 
50 Nm (5.0mkg, 36 ft-lb) 



• Loosen the ring nut © completely and 
retighten it to specification. 



WARNING: 



Do not over-tightening. 



€1 



Ring Nut © (Final Tightening): 
3Nm (0.3m-kg,2.2 ft.lb) 



• Check the steering stem by turning it lock to 
lock. If there is any binding, remove the 
steering stem assembly and inspect the 
steering barings ® . 

Refer to "CHAPTER 6. STEERING HEAD" 
for more details. 

• Install the washer © . 

• Install the ring nut (upper)© . 

NOTE: 



The tapered side of ring nut must face down- 
ward. 



• Finger tighten the ring nut © , then align 
the slots of both ring nuts. If not aligned, 
hold the lower ring nut © and tighten the 
other until they are aligned. 



2-30 



ADJ %m 



WHEEL BEARINGS CHECK/TIRES CHECK 



• Install the lock washer (3) 
NOTE: 



Make sure the lock washer tab is placed in 
the slots. 



• Install the steering crown (2) and tighten 
the steering stem nut® to specification. 



m 



N ut (Steering Stem) : 

HONmOI.Om-kg, 80ft-lb) 



•Tighten the pinch bolts to specification. 



fl 



Pinch Bolt (Steering Crown): 
20Nm(2.0m-kg I 14ftlb) 



11. Install: 

• Components in above list (steps "6 — 2") 



©I 



Handlebar Lower Holder: 
40Nm(4.0 m-kg,29ft-lb) 



~N 



WHEEL BEARINGS CHECK 

Front Wheel 

1. Check: 
.Front wheel bearings 

Raise the front end of the motorcycle, and 
spin the wheel by hand. Touch the axle or 
front fender while spinning the wheel. 
Excessivevibration -> Replace bearings. 




Rear Wheel 

1. Remove: 

• Rear wheel 

2. Check: 

• Bearing movement 
With the fingers. 

Roughness/Wear -»• Replace. 



TIRES CHECK 



WARNING: 



Do not attempt to use tubeless tires on a wheel 
designed for tube type tires only. Tire failure 
and personal injury may result from sudden 
deflation. 



Wheel 


Tire 


Tube type 


Tube type only 


Tubeless 


Tube type of tubeless 



2-31 



TIRES CHECK 



JNSP 
ADJ 



Ml 



<Q™. 



BELESS 



£) 




TJ 





Be sure to install the correct tube when using 
tube type tires. 



|~1 Tubeless tire 
[TJ Tube type tire 



; Tire 
□ Wheel 
(T) Air valve 

(2) Aluminum wheel (tubeless type) 
(D Tube 
(4) Aluminum wheel (tubetype) 



WARNING; 



This motorcycle is fitted with "V" range tires 
(for super high speed running). The following 
points must be observed in order for you to 
make fully effective use of these tires. 

• Never fail to use "V" range tires in tire re- 
placement; "S" or "H" tires may be in danger 
of bursting at super high-speeds. 

• New tires have a relatively poor adhesion 
on the road surface so do not allow them to 
be subjected to high speed load from maximum 
speed until after a break-in run of approx. 
100km (60mi). 

• Before any high-speed runs, remember to allow 
a sufficient warm-up time for the tires. 

• Always use the correct tire inflation pressure 
according to the operation conditions. 



1 . Measure: 
•Tire pressure 
Out of specification - 



Adjust. 



Basic weight: 
With oil and full fuel tank 


274 kg (6041b) 


Maximum load* 


225 kg (4961b) 


Cold tire pressure 


Front 


Re3r 


Up to 90 kg (198 lb) load" 


235 kPa 

(2.4 kg/cm 2 , 

34 psi) 


255 kPa 

(2.6 kg/cm 2 , 

36 psi) 


90kg (1981b)- 
Maximum load" 


235 kPa 

(2.4 kg/cm 2 , 

34 psi) 


275 kPa 

(2.8 kg/cm 2 , 

40 psi) 


Highspeed riding 


235 kPa 

(2.4 kg/cm 2 , 
34 psi) 


255 kPa 

(2.6 kg/cm 2 , 

36 psi) 



'Load is the total weight of cargo, rider, passenger, and 
accessories. 



2-32 



INSP 
ADJ 



<a 



TIRES CHECK 




WARNING: 



• Tire inflation pressure should be checked 
and adjusted when the temperature of the 
tire equals the ambient air temperature. 

Tire inflation pressure must be adjusted ac- 
cording to total weight of cargo, rider, pas- 
senger, and accessories (fairing, saddlebags, 
etc. if approved for this model), and vehicle 
speed. 

• Proper loading of your motorcycle is impor- 
tant for the handling, braking, and other per- 
formance and safety characteristics of your 
motorcyle. Do not carry loosely packed items 
that can shift. Securely pack your heaviest 
items close to the center of the motorcycle, 
and destribute the weight evenly from side 
to side. Properly adjust the suspension for your 
load, and check the condition and pressure of 
your tires. NEVER OVERLOAD YOUR 
MOTORCYCLE. Make sure the total weight 
of the cargo, rider, passenger, and accessories 
(fairing, saddlebags, etc. if approved for this 
model) does not exceed the maximum load of 
the motorcycle. Operation of an overloaded 
motorcycle could cause tire damage, an ac- 
cident, or even injury. 



2. inspect: 
• Tire surfaces 
Wear/Damage 



Replace. 




Minimum Tire Tread Depth: 
(Front and Rear) 
1.0 mm (0.04 in) 



(T) Tread depth 

© Side wall 

CD Wear indicator 



WARNING; 



• It is dangerous to ride with a wornout tire. 
When a tire tread begins to show lines, replace 
the tire immediately. 

• Patching a punctured tube is not recommended. 
If it is absolutely necessary to do so, use great 
care and replace the tube as soon as possible 
with a good quality replacement. 



2-33 



WHEELS CHECK/IGNITION TIMING CHECK 



INSP 
ADJ 



M 




WHEELS CHECK 

1. Inspect: 
•Alumi num wheels 
Damage/Bends -> Replace. 

NOTE: 



Always balance the wheel when a tire or wheel 
has been changed or replaced. 



WARNING. 



Never attempt even small repairs to the wheel. 

2. Tighten: 

• Valve stem locknut 



« 



Valve Stem Locknut: 

1.5 Nm (0.15 rn-kg, 1.1 ft-lb) 



WARNING: 



Ride conservatively after installing a tire to 
allow it to seat itself properly on the rim. 

ELECTRICAL 

IGNITION TIMING CHECK 

1. Check: 
• Ignition timing 
By the following steps. 



Ignition timing check steps: 

• Remove the timing plug (T) . 

• Connect the Timing Light (2) (YU-08037) 
to No. 1 or No. 2 cylinder spark plug lead. 

•Warm up the engine and let it idle at the 
specified idle speed of 1,000 r/min. 

• Visually check the stationary pointer (D in 
the timing window to vertify it is within 
the required firing range indicated on the 
flywheel. 

Incorrect firing range -* Check flywheel and/ 
or pickup assembly (tightness damage). 
Refer to "CHAPTER 7, ELECTRICAL" for 
further information. 



(4) Firing range for the No. 1 cylinder 
(I) Firing range for the No. 2 cylinder 



2-34 



INSP |pl 

AD J \sil 



BATTERY INSPECTION 




BATTERY INSPECTION 

1. Inspect: 
• Battery fluid level 

Battery fluid level low^ Fill. 

Fluid level should be between upper and 

lower level marks. 



i 



Upper level 
Lower level 



Refill with distilled water only; tap water 
contains minerals harmful to a battery. 



WARNING: 



Battery electrolyte is dangerous; it contains 
sulfuric acid and therefore is poisonous and 
highly caustic. 
Always follow these preventive measures: 

• Avoid bodily contact with electrolyte as it 
can cause severe burns or permanent eye injury. 

• Wear protective eye gear when handling or 
working near batteries. 

Antidote (EXTERNAL): 

• SKIN — Flush with water. 

• EYES — Flush with water for 15 minutes and 
get immediate medical attention. 

Antidote (INTERNAL): 

• Drink large quantities of water or milk follow 
with milk of magnesia beaten egg, or vegetable 
oil. Get immediate medical attention. 

Batteries also generate explosive hydrogen gas, 
therefore you should always follow these 
preventive measures: 

• Charge batteries in a well-ventilated area. 

• Keep batteries away from fire, sparks, or open 
flames (e.g., welding equipment, lighted 
cigarettes, etc.) 

• DO NOT SMOKE when charging or handling 
batteries. 

KEEP BATTERIESAND ELECTROLYTE OUT 
OF REACH OF CHILDREN. 



2-35 



BATTERY INSPECTION 




<a 



INS P 
ADJ 



2. Remove: 

• Battery 

3. Inspect: 

• Battery fluid specific gravity 
Out of specification ->■ Charge. 

CAUTN3N: 



Always charge a new battery before using it to 
ensure maximum performance. 



Charging Current: 

1.4amps/10 hrs 
Specific Gravity: 

1.280at20 u C(68°F) 




4. Install: 

• Battery 

5. Connect: 

• Breather hose 

Be sure the hose is properly attached and 
routed. 

CAUTION: 

When inspecting the battery, be surethe breather 
hose is routed correctly. If the breather hose 
touches the frame or exits in such a way as to 
cause battery electrolyte or gas to exit onto the 
frame, structural and cosmetic damage to the 
motorcycle can occur. 

(Tj Battery 

(2) Pass through guide 

6. Inspect: 

• Breather hose 
Obstruction-* Remove. 
Damage -> Replace. 



2-36 



INSP 
ADJ 



M 



BRAKE LIGHT SWITCH ADJUSTMENT/ 
SPARK PLUG INSPECTION 




BRAKE LIGHT SWITCH ADJUSTMENT 

1. Adjust: 

• Brake light operating timing 
Hold the main body ® of the switch with 
your hand so it does not rotate, and 
turn the adjuster (2) until the operating 
timing is correct. 



SPARK PLUG INSPECTION 

1. Inspect: 

• Electrode (D 
Wear/Damage^ Replace. 
.Insulator color (f) 
Normal condition is a medium to light 
tan color. 

Distinctly different color -* Check the 
engine condition. 
(3) Spark plug gap 

2. Clean: 

•Spark plug 

Clean the spark plug with a spark plug 
cleaner or wire brush. 

3. Inspect: 
•Spark plug type 

Incorrect-^ Replace 



Standard Spark Plug: 
DPR8EA-9(NGK) 
X24EPR-U9 (N.D.) 



4. Measure: 

•Spark plug gap 
Out of specification 
Use a wire gauge. 



Regap. 




Spark Plug Gap: 

0.8- 0.9 mm (0.031 _ 0.035 in) 



5. Tighten: 
•Spark Plug 



NOTE: 

Before installing a spark plug, clean the gasket 
surface and plug surface. 



a 



Spark Plug: 

17.5Nm (1.75 m-kg, 12.5ft-lb) 



2-37 



HEADLIGHT BULD REPLACEMENT 



40t INSP 

5a. adj 



NOTE: 

If a torque wrench is not available when you are 
installing a spark plug, a good estimate of the 
correct torque is 1/4 to 1/2 turns part finger 
tight. Have the spark plug torqued to the correct 
value as soon as possible with a torque wrench. 



r~ 




r^ 



HEADLIGHT BULB REPLACEMENT 

1. Remove: 

* Headlight lens unit (T) 

2. Disconnect: 

• Headlight lens unit leads 



3. Remove: 
• Bulb 
Turn the bulb holder (T) counterclockwise 
to release bulb. 



WARNING: 



Do not touch headlight bulb when it is on as the 
bulb generates enormous heat; keep flammable 
objects away. 

4. Install: 

• Bulb (new) 

Secure the new bulb with the bulb holder. 

CAUTION; 

Avoid touching glass part of bulb. Also keep it 
free from oil otherwise, transparency of glass, 
bulb life and illuminous flux will be adversely 
affected. If oil gets on bulb, clean itwith a cloth 
moistened thoroughly with alcohol or lacquer 
thinner. 

Don't touch 

5. Install: 

• Headlight lens unit 



2-38 



K 



INSP 
ADJ 



HEADLIGHT BEAM ADJUSTMENT/FUSE INSPECTION 




HEADLIGHT BEAM ADJUSTMENT 
1. Adjust: 
• Headlight beam (horizontally) 



Horizontal Adjustment 



Right 



Left 



Turn adjusting screw clockwise 



Turn adjusting screw counter- 
clockwise 



2. Adjust: 

• Headlight beam (vertically) 



I 



Higher 



Vertical Adjustment 



Turn the adjusting screw clock- 
wise 



Lower 



Turn the adjusting screw counter- 
clockwise. 



FUSE INSPECTION 

The fuse panel is located under the top cover 
and seat. 
1. Inspect: 

• Fuses 

• Main fuse 
Defective^ Replace. 

Blown fuse (new)^ Inspect circuit. 

CAUTtON; 

Do not use fuses of higher amperage rating 
than those recommended. 
Substitution of a fuse of improper rating can 
cause extensive electrical system damage and 

possibly a fire. 



Spare fuses 


Description 


Amperage 


Quantity 


Main 


30A 


1 


Headlight 


15A 


1 


Signal 


15A 


1 


Ignition 


10A 


1 


Reserve 


30A 


1 


15A 


1 


10A 


1 



2-39 



CHAPTER 3. 
ENGINE OVERHAUL 



ENG 



\» 



ENGINE REMOVAL 3-1 

PREPARATION FOR REMOVAL 3-1 

CARBURETOR 3-2 

RADIATOR 3-3 

V-BOOST CONTROL CABLE AND AIR BAFFLE PLATE 3-4 

FOOTREST (RIGHT) AND BRAKE PEDAL 3-4 

FOOTREST (LEFT) AND CLUTCH RELEASE CYLINDER 3-5 

EXHAUST PIPE AND MUFFLER 3-6 

SERVO MOTOR 3-7 

ENGINE REMOVAL 3-7 

V-BOOST 3-7 

ENGINE DISASSEMBLY 3-8 

CYLINDER HEAD AND CAMSHAFT 3-8 

STARTER IDLE GEARS AND FLYWHEEL 3-11 

CLUTCH AND OIL PUMP DRIVE GEAR 3-12 

WATER PUMP AND THERMOSTATIC VALVE 3-13 

STARTER MOTOR AND BREATHER COVER 3-14 

OIL PAN AND OIL PUMP 3-14 

CRANKCASE DISASSEMBLY 3-15 

UPPER CRANKCASE 3-16 

TRANSMISSION 3-17 

LOWER CRANKCASE 3-17 

INSPECTION AND REPAIR 3-19 

CYLINDER HEAD 3-19 

VALVE, VALVE GUIDE. AND VALVE SEAT 3-20 

CAMSHAFT. CAM CHAIN. AND CAM SPROCKET 3-27 

PISTON. PISTON RING. AND PISTON PIN 3-29 

STARTER DRIVES 3-32 

PRIMARY GEARS 3-33 

CLUTCH 3-33 

O I L PUMP 3-35 

OIL GALLERY PIPE 3-36 

CRANKSHAFT 3-36 

BLANCER SHAFT 3-40 

TRANSMISSION 3-42 

BEARING 3-43 

CIRCLIPS AND WASHERS 3-43 

MIDDLE GEAR SERVICE 3-44 

DRIVE AXLE POSITIONING 3-46 

REMOVAL 3-50 

INSPECTION 3-51 

ASSEMBLY 3-51 

MIDDLE DRIVEN GEAR BEARINGS 3-52 



ENG % m 



ENGINE ASSEMBLY AND ADJUSTMENT 3-55 

LOWER CRANKCASE 3-55 

TRANSMISSION ....,,.,., . . . . . . , . . . . . . . . . . " . . . . . . . . . . , . • 3"58 

UPPER CRANKCASE '. '. '. '. '. ' ' ' ' '. ' ' ' ' ' " ' " " ' " " " " ' " " ' " ' " " " " " " " " . 3-59 
CRANKCASE ASSEMBLY .............. . . . . . . . . . . . . . . ...... . 3-61 

OIL PUMP AND OIL PAN . 3-63 

BREATHER COVER AND STARTER MOTOR 3-65 

WATER PUMP AND THERMOSTATIC VALVE 3-65 

CLUTCH AND OIL PUMP DRIVE GEAR 3-66 

FLYWHEEL AND STARTER IDLE GEAR 3-69 

CYLINDER HEAD AND CAMSHAFT 3-71 

OIL DELIVERY PIPE AND CYLINDER HEAD 3-77 

V-BOOST 3 _ 78 

REMOUNTING ENGINE 3-79 




^ 



^\ 



ENG 



%m 



ENGINE REMOVAL 



ENGINE OVERHAUL 

ENGINE REMOVAL 

NOTE: 

It is not necessary to remove the engine in 
order to remove the following components: 
.Clutch 

• Carburetor 

• Water pump 

• AC magneto 

PREPARATION FOR REMOVAL 

1. Remove all dirt, mud, dust, and foreign 
material before removal and disassembly. 

2. Use proper tools and cleaning equipment. 
Refer to "CHAPTER 1. SPECIAL TOOL" 
section. 




NOTE: 

When disassembling the engine, keep mated parts 
together. This includes gears, cylinders, pistons, 
and other parts that have been "mated" through 
normal wear. Mated parts must be reused as an 
assembly or replaced. 



3. During engine disassembly, clean all parts 
and place them in trays in the order of 
disassembly. This will speed up assembly 
time and help assure that all parts are 
correctly reinstalled in the engine. 



4. Drain engine oil completely. 

Refer to "CHAPTER 2. ENGINE OIL 
REPLACEMENT" section. 

5. Drain coolant completely. 

Refer to "CHAPTER 4. COOLANT RE- 
PLACEMENT" section. 



3-1 



ENGINE REMOVAL 



ENG 



%m 




CARBURETOR 
1. Remove: 
•Top cover © 
• Covers (left and right) (5) 



2. Remove: 

• Holders (carburetor overflow hose) (T) 

3. Loosen: 

•Screws (air cleaner joint) (2) 



4. Remove: 
•Ventilation hose (crankcase) (D 
• Air cleaner assembly (5) 



5. Disconnect: 
• Fuel hose (D 



6. Disconnect: 

•Vacuum hose (ignition advance) ® 

7. Loosen: 

• Screws (carburetorjoint) 

8. Remove: 

• Carburetorjoint cover (left and right) (2) 



3-2 



ENG 


\m 



ENGINE REMOVAL 




9. Remove: 

• Electrical components board (T) 

• Throttle cable cylinder (?) 
10. Disconnect: 

• All leads and cables 



11. Remove: 

• Carburetor assembly 



NOTE: 

Cover the carburetor with a clean rag to prevent 
dirt or foreign matter into the carburetor. 



RADIATOR 
1. Remove: 
*Radiator covers 



2. Remove: 
*Bolts (radiator) 

3. Disconnect: 
*Upper hose (T) 
• Lower hoses (f) 



4. Disconnect: 

*Fan motor coupler 

5. Remove: 
*Radiator assembly 
• Horn 



"> 



3-3 



ENGINE REMOVAL 



ENG 



%m 




6. Disconnect: 

• All hoses and leads (conduit) 

7. Remove: 
*Screws (conduit) 



V-BOOST CONTROL CABLE AND AIR 
BAFFLE PLATE 

1. Disconnect: 
*Control cable (V-boost) © 



2. Disconnect: 
*Spark plug caps 

3. Straighten: 

*Tabs (front baffle plate) ® 



4. Remove: 

• Air baffle plate (front) (D 
•Air baffle plate (rear) (2) 



FOOTREST (RIGHT) AND BRAKE PEDAL 

1. Remove: 
*Footrest (right) (D 
•Brake pedal assembly (2) 
*Brake master cylinder (3) 



3-4 



ENG 


%m 



ENGINE REMOVAL 




2. Disconnect: 

•Ground lead 

3. Remove: 

• Rear brake switch (2) 



FOOTREST (LEFT) AND CLUTCH RELEASE 
CYLINDER 

1. Remove: 

• Footrest (left) 

• Change pedal assembly (2) 

• Middle gear case cover (D 



2. Remove: 

• Seat 

•Side cover (left) 

3. Disconnect: 

• All leads (engine) 

4. Remove: 
•Band 



5. Remove: 
• Clutch release cylinder 



6. Remove: 
•Spring 

7. Disconnect: 
•Rubber boot (2) 



^ 



3-5 



ENGINE REMOVAL 



■ ■ 

ENG %j 




EXHAUST PIPE AND MUFFLER 

1. Remove: 
• Flange bolts (front exhaust pipe) 



2. Loosen: 

*Bolts (front exhaust pipe) © 

3. Remove: 

• Front exhaust pipes © 



4. Remove: 

*Bolt (muffler chamber) 

5. Loosen: 

*Bolts (muffler) © 

6. Remove: 

*Bolts (muffler bracket) ® 
• Mufflers 



7. Remove: 

*Screws (rear exhaust protector) 
• Covers (rear exhaust) (D 



8. Remove: 

• Clamps (rearexhaust pipes) © 
*Protector © 

• Rear exhaust pipes © 



3-6 



ENG 


\. 



IWgJAIf REMOyAL 




SERVO MOTOR 

1. Remove: 

*Screws (servo motor bracket) 
*Servomotor (T) 

2. Disconnect: 

*Servo motor coupler 



ENGINE REMOVAL 

1 . Place a suitable stand under the engine. 

2. Remove: 

*Bolt (engine) (D 
*Bolts (down tube) (2) 
*Down tube frame (right) (§) 



3. Remove: 

*Engine assembly 
from right side. 

NOTE: 



Remove the rear cylinder head cover if diffi- 
culties are encountered with any of the previous 
steps. 



V-BOOST 

1. Remove: 
• V-boost assembly (j) 

NOTE: 

Working in a crisscross pattern, loosen the bolts 
1/4 turn each. Remove them after all are 
loosened. 



3-7 



ENGINE DISASSEMBLY 









r- 



ENG 



*m 





' ! #3 


#2 ® ®' 


T— ^#1 




ENGINE DISASSEMBLY 
CYLINDER HEAD AND CAMSHAFT 
Rear Cylinder Head 

1. Remove: 

Cylinder head covers (rearand front) 

• Gaskets 

• Spark plugs 

© Front 

(2) Front cylinder 

(D Rear cylinder 

2. Remove: 

• Crankcase cover plate © 
•Special washer (2) 
•Timing plug (§) 

NOTE: 

Check for clog of oil passage © in the bolt. 
If any, clean the oil passage. 



3. Align: 

• Flywheel "T-1" mark © with stationary 
pointer (2) on crankcase cover 



4. Remove: 
•Cam chain tensioner (rear)® 



5. Remove: 
• Chain guides © , (2) 
•Camshaft caps (3), (4) 
They was marked "1-2" © and "E-2" (4). 



3-8 



ENG 



%• 



ENGINE DISASSEMBLY 




6. Remove: 

•Bolts (cam chain sprocket) 
Use 22 mm wrench to hold camshaft. 



7. Remove: 

'Camshaft caps , (2) , ® , ® , (D , (6) 

NOTE: 

When loosing camshaft cap bolts, be sure cam- 
shaft cam lobes do not touching valve lifters. 



8. Remove: 

• Camshafts 

• Sprockets 

Slip the sprockets from mounting boss on 
camshaft. 

NOTE: 

Fasten a safety wire to the cam chain. 



9. Remove: 
• Lock pin 
*Water jacket joint 



10. Remove: 

• Nuts (cylinder head) 
Use 8 mm Wrench Adapter (YM-28897). 

NOTE: 

Follow numerical order shown in photo. Start 
by loosening each nut 1/2 turn until all are 
loose. 



3-9 



ElMtilNE DISASSEMBLY 



ENG 




1 1 . Remove: 

• Oil delivery pipe 



NOTE: 

When removing the pipe, be sure not to lose the 
washers that may fall out. 

• Cylinder head 



12. Remove: 

• Cam chain guide (rear) 

• Gasket (2) 

• Dowel pins (3) 



Front Cylinder Head 

When removing the front cylinder head, repeat 
the rear cylinder head removal procedure. 
However, note the following points. 
1. Rotate: 
• Crankshaft 
Counterclockwise 360" plus an added 70° 
(430"total)from the "T-1" mark. 




2. Align: 
• Flywheel "T-2" mark with stationary 
pointer (§) on crankcase cover 



3. Mark: 
• Pistons 
With piston number designations as shown. 



3-10 



ENG 



m 



ENGINE DISASSEMBLY 




STARTER IDLE GEARS AND FLYWHEEL 

1. Remove: 
*Crankcase cover (left) © 

• Gasket 

• Dowel pins 



2. Remove: 

*Starter idle gears © 



3. Remove: 
•Bolt (flywheel) © 
• Plain washer <§) 
•Pin (D 

NOTE: 

Check for clog of oil passage © in the bolt. 
If any, clean the oil passage. 



4. Remove: 
• Flywheel 
Use the Flywheel Puller (YU-33270) © 
with the Puller Adapter (YM-33282) © ■ 

NOTE: 

When removing the flywheel, do not allow the 
oil baffle plate © to touch the projections © 
on the flywheel. 



^ 



3-11 



r- 



ENGINE DISASSEMBLY 



ENG 


\» 




^,trij 


j^ 


tig 


Ijijj 






/ 1 


^ 




™ 


P 


M 


a 




^m! 


'« 


\"* 







o 

ID 




5. Remove: 

• Woodruff key (T) 

• Starter clutch gear (5) 



6. Remove: 
• Oil baffle plate ® 



CLUTCH AND OIL PUMP DRIVE GEAR 

1. Remove: 
• Crankcase cover (right) (J) 



NOTE: 

Working in a crisscross pattern, loosen the bolts 
1/4 turn each. Remove them after all are 
loosened. 

• Gasket 

• Dowel pins 
2. Remove: 

• Bolts (clutch spring) (7) 

• Plate washer (2) 

• Clutch spring (3) 
•Spring seat (4) 

• Pressure plate (5) 

• Friction plate (§) 

• Clutch plates (7) 

• Friction plates (f) 

• Push rod (D 



3-12 



ENG 



4 



ENGINE DISASSEMBLY 




3. Straighten the lock washer tabs. 

4. Loosen: 

• Nut (clutch boss) ® 
Use the Clutch Holder (YM-91042) (2) to 
hold the clutch boss. 






5. Remove: 

• Nut (clutch boss) ® 

• Lock washer (2) 

• Clutch boss (D 
•Thrust washer ® 

• Clutch housing (5) 



~> 



6. Remove: 

• Circlip ® 

• Oil pump drive gear 



WATER PUMP AND THERMOSTATIC VALVE 

1. Remove: 

• Waster pump cover/ Water pump cable ® 

• Gasket 

• Dowel pins 



2. Remove: 

• Thermostat assembly ® 



3-13 



ENGINE DISASSEMBLY 



ENG 


\m 





STARTER MOTOR AND BREATHER COVER 

1. Remove: 
• Starter motor 



2. Remove: 

• Breather cover 

• Breather cover spacer (f) 

• Oil pipe (|) 



OIL PAN AND OIL PUMP 

1. Remove: 
• Oil filter cover 



2. Remove: 

• Oil pan 

• Gasket 

• Dowel pins 



3. Remove: 

• Oil pump assembly 

• Dowel pins 



3-14 



ENG 




ENGINE DISASSEMBLY 




NOTE: 

At this stage it is possible to replace the piston, 
connecting rod, and big-end bearing by simply 
removing the connecting rod nut. None of the 
steps below are necessary to replace the above 
components. 



4. Straighten the bracket tabs 

5. Remove: 
•Oil pipe (2) 

• Main oil gallery pipe (§) 



6. Remove: 
•Damper (oil pump pipe) 
•Oil pump pipe (§) 



CRANKCASE DISASSEMBLY 

1. Remove: 
•Retainer (main axle bearing) 
•Retainers (middle gear bearing) (§) 
Use the #40 Torx Driver (YU-29843-7). 



2. Remove: 

•Bolts (middle driven gear housing) ® 



^ 



^ 






3-15 



r- 



ENGINE DISASSEMBLY 




-©*-<§ 



OJLQ 

— r " v 



J 




^^\kJf 



ENG 



%m 




3. Remove: 

• Bolts (crankcase) 



NOTE: 

• Remove the bolts starting with the highest 
numbered one. 

• The embossed numbers in the crankcase 
designate the crankcase tightening sequence. 



* With washer 
A.; UPPER CASE 
fBl LOWERCASE 



3. Remove: 
• Crankcase (upper) 
Use a soft hammer. 
NOTE: 



Pull out the crankcase (upper) while pulling up 
the cam chain. 



• Dowel pins 



UPPER CRANKCASE 

1. Remove: 

• Connecting rod caps CD 

• Connecting rod/Piston assembly 

CAUTION: 



Do not hammer out the connecting bolts to 
remove the connecting rod assembly. 



3-16 



ENG 



ENGINE DISASSEMBLY 



2. Remove: 

• Crankshaft 

• Plane bearings (crankshaft/connecting rods/ 
balancer shaft) 

NOTE: 

Identify each plane bearing position very care- 
fully so that it can be reinstalled in its original 
place. 




3. Remove: 

• Piston pin clip © 

• Piston pin (?) 
*Piston (3) 



TRANSMISSION 

1. Remove: 

• Balancer shaft 
*Main axle assembly (2) 

*Drive axle assembly (§) 
•Middle driven gear assembly (4) 

• Plane bearings (Crankshaft/balancer shaft) 

NOTE: 

Identify each plane bearing position very care- 
fully so that it can be reinstalled in its original 
place. 



~> 




LOWER CRANKCASE 

1. Remove: 
*Shift shaft assembly 



(T) Shift lever 1 
(2) Shift lever 2 



3-17 



ENGINE DISASSEMBLY 



ENG 





2. Unhook: 
•Tension spring (V) 

3. Remove: 

• Shift cam stopper lever (2) 



4. Remove: 

• Bearing retainer (shift cam) ® 

• Guide bars © 

• Shift forks (3) 

• Shift cam (4) 

NOTE: 



Note the position of each part. Pay particular 
attention to the location and direction of shift 
forks. 



5. Remove: 

• Circlip © 

• Oil pump idle gear (2) 



r~ 



3-18 



ENG 


\» 



INSPECTION AND REPAIR 



'b ooo 

E ' 2 3 4 

poo OO 

112 3 4 


\ 




INSPECTION AND REPAIR 
CYLINDER HEAD 

1. Remove: 

• Valve pads 

• Lifters 

o Spark plugs 

NOTE: 




Identify each lifter and pad position very care- 
fully so that it can be reinstalled in its original 
place. 

2. Attach: 

oValve Spring Compressor (YM-04019) (f) 







_— — © 


n 

i \ 


c^^* 


» — © 

__ (D 


F 


\ 


c^ek 


__ — © 






\ m^s 


C—-® 


i 


h> s 


J \ 





3. Remove: 
•Valve retainers (£) 

• Valve spring seat © 
oValve springs (3) 

• Oil seal (?) 
oValve spring seat (5) 

• Valve (f) 




NOTE: 

Deburr any deformed valve stem end. Use an oil 
stone to smooth the stem end. 

(T) Deburr 
(g) Valve stem 

4. Eliminate: 
• Carbon deposit 
Use rounded scraper. 



NOTE: 

Do not use a sharp instrument and avoid damag- 
ing or scratching. 

• Spark plug threads 
oValve seat 

• Cylinder head 



3-19 



INSPECTION AND REPAIR 




H 


2) 




1 


; i 


I J 




ENG w 



5. Measure: 
• Cylinder headwarpage 
Under specification -* Resurface. 
Over specification -+ Replace. 




Cylinder Head Warp Limit: 

Less than 0.03 mm (0.0012 in) 



VALVE, VALVE GUIDE, AND VALVE SEAT 

Intake and Exhaust Valve 
1. Inspect: 
*Valve face 
*Stem end 
Wear/Pitting/Out of specification -* 
Replace. 




Minimum Thickness (Service limit) (j) 

0.7 mm (0.028 in) 
Beveled© : 0.5 mm (0.020 in) 
Minimum Length (Service limit) (f) : 

4.0 mm (0.16 in) 



r- 




2. Measure: 
• Valve stem clearance 
Out of specification -> Replace either valve 
and/or guide. 
Use the Micrometer and Bore Gauge. 



m 




Valve Stem Clearance 


Maximum 




Intake 


0.010 "0.037 mm 
(0.0004 ~ 0.0015 in) 


0.08 mm 
(0.0031 in) 




Exhaust 


0.025 ~ 0.052 mm 
(0.0010- 0.0020 in) 


0.10 mm 

(0.0039 in) 





(D Valve 

(2) Bore Gauge 

(3) Valve guide 



[ft] Valve stem outside diameter 
[B] Valve guide inside diameter 



3-20 



ENG 


*^» 


INSPECTION AND REPAIR 












3. Inspect: 
•Valve stem end 
Mushroom shape/Larger diameter than rest 
of stem -* Replace valve, valve guide, and 
oil seal. 




R 


II — 


:®^i 




m 




i l 


^ 


— ^ 


-^ 

j 








4. Measure: 

• Valve stem runout 
Out of specification 



Replace. 




Maximum Runout: 
0.01 mm (0.0004 in) 



Valve Guide 
NOTE: 



• Always replace valve guide if valve is replaced. 

• Always replace oil seal if valve is removed. 



1. Inspect: 
• Valve guide 
Wear/Oil leakage into cylinder 



Replace. 




2, Remove: 
• Valve guide 
Use the Valve Guide Remover (YM-01 122) 
©■ 
NOTE: 

Heat the head in an oven to 100°C (212°F) to 
ease guide removal and installation and to 
maintain correct interference fit. 



3. Install: 

•Circlip (new) 

• Valve guide (Oversize) 
Use the Valve Guide Remover (YM-01 122) 
CD with the Valve Guide Installer (YM- 
01129) (D . 



3-21 



WSPECTDN AND REPAIR 



I ENG %J 




"■ 



"~ 





NOTE: 

AftEr installing val/e gude: 

*Use the 5 5 mm Val/e Guiie Reamer (bTM - 

01196) (7) tD obtain proper vate guide/ 

val/e stem clearance , 
• ReCUtj the val/e seat 

(flciclfe 

(T) Valve guide 

Val/e Seat 
1. Iispect 
*Val/e seat 
W ear/Pitting /Val/e replacement-*! 
Resurface seat at 45° angie. 

mmtoHv 



Ciean val/e seat if pitted or worn using a 45° 
Val/e Seat Cutter &TM -91043) © , When twist- 
ing cutter, keep an even downward pressure to 
prevent chatter m arks . 



Cut sections as iblbws 


Sectbn 


Cutter 


A 


30° 


B 


450 


C 


60° 



, M easure : 

• Val/e seat width 

. AppV: 

• Mechanics bliiig dye (Dykem ) 
To val/e and seat 

*Fine grinding com pound (sm a lam ount) 

Gmund surface of val/e face. 
. Positbn: 

• Valvesl 

litD cylhderhead . 

Spin it rapidiy back and forth, then lift 
val/e and clean ofEaHgrhdiig compound. 
. aspect: 

• Vatvd seat surface 

W herever val/e seat and val/e face made 
contact bliiig will have been removed. 



3-22 



ENG 



\m 



1SPECTDN AND REPAIR 




1 H 




■ 


\ \ 
1 \ 
1 \ 






1 a ^ 

1 






1 










1 \ 






iV. 


V. 




1 b v - 


"^ 




1 


) 






6 . M easuiE : 

• Valvel seatwiith 
Out of speciacation/R em aining pitting/ 
Varatbn of val/e seat width -n Cut vale 
farther. 

Remove just enough m aterial to achieve satisfac- 
tory seat. 




Seat Width: 

Standard: 1.0 ± o.i mm 

(0.039 il 0.004 in) 

Wear limit: 1.4 mm (0.055 in) 



Val/e seat recutting stEps are necessary if: 
*Val/e seat is uniform around perm eter of 

val/e face but too wile or not centered on 

val/e face . 


Valve Seat Cutter Set 


Desired result 


Use 
either 


30° outtor 


To center the seat or 
to reduce its w rlth 


45° cutter 


60° cutter 


•Valvd face indicates that valve seat is 
centered on valve face but is too wile (pee 
"a" diagram ) . 


Valve Seat Cutter Set 


Desired result 


Use 
lightly 


30° cutter 


To reduce valve seat 
width to 1.0 mm 
(0.039 in) 


60° cutter 


•Valvd seat is ±i the m ildfe of the val/e face 
but too nartow (pee To" diagram ) . 
- 


Valve Seat Cutter Set 


Desired Result 


Use 


45° cutter 


To achieve a uniform 
valve seat width of 
1.0 mm (0.039 in) 


•Valve seat' e too narrow and right up near 
valve m argil (see *c" diagram ) . 


Valve Seat Cutter Set 


Desired Result 


Use 


30° cutter, first 


To center the seat and 
to increase its width 


45° cutter 









3-23 



INSPECTION AND REPAIR 



ENG 



\m 



• Valve seat is too narrow and is located down 
near the bottom edge of the valve face 
(see diagram "d"). 



Valve Seat Cutter Set 



Use 



60° cutter, first 



Desired Result 



45° cutter 



Tn f enter the spat and 

to increase its width 




Valve/Valve Seat Assembly Lapping 

1. Apply: 

• Coarse lapping compound (small amount) 
To valve face. 

• Molybdenum disulfide oil 
To valve stem. 

2. Position: 

• Valves 

In cylinder head. 

3. Rotate: 

• Valve 

Turn until valve and valve seat are evenly 
polished, then clean off all compound. 

4. Apply: 

• Fine lapping compound (smallamount) 
To valve face. 

5. Repeatsteps2 and 3. 



NOTE: 

Be sure to clean off all compound from valve 
face after every lapping operation. 

6. Inspect: 

• Valve face 

Not yet uniformly smooth -+ Repeat proce- 
dure from step 1. 

7. Apply: 

• Mechanics bluing dye (Dykem) 
To valve face and seat. 

8. Rotate: 

• Valve 

9. Inspect: 

• Valve face 

Valve must make full seat contact indicated 
by grey surface all around. The valve face 
where bluing was removed. 
Faulty contact ->■ Replace. 
(See procedure below) 



3-24 



ENG 



^^ 



INSPECTION AND REPAIR 




10. Apply: 
.Solvent 
Intoeach intakeand exhaust port. 

NOTE: 



Pour solvent into intake and exhaust ports only 

after completion of all valve work and assembly 
of all head parts. 



11. Check: 

.valve seals 
Leakage past valve seat 
(See procedure below) 



Replace valve. 



(2) Valve guide 



Relapping steps: 






• Disassemble head parts. 






• Repeat lapping steps usin 


gfine lappin 


g corn- 


pound. 






• Clean all parts thoroughly 






• R'eassemble and check 


for leakage 


again 


using solvent. 






• Repeat steps as often as 


necessary to 


effect 


a satisfactory seal. 










Valve Spring 

This engine uses two springs of different sizes 
to prevent valve float or surging. Valve spring 
specifications show the basic value character- 
istics. 



(T) Outer spring 
(D Inner spring 



1. Measure: 
• Spring free length 
Out of specification 



Replace. 




Minimum Free Length: 

Outer: 38.90 mm (1.531 in) 
Inner: 37.45 mm (1.474 in) 



3-25 





INSPECTION AND REPAIR 


ENG 


V 






§ 




2. Measure: 
• Spring force (installed length) 
Out of specification -> Replace. 




Valve Compressed Force: 

Outer: 13.3 " 15.7 kg {29.3- 34.6 lb) 

at 33.8 mm (1.331 in) 

Inner: 6.29 -7.39kg (13.9 ~ 16.31b) 

at31.8 mm (1.75 in) 











r^ 




Valve Lifter 
1. Inspect: 
• Valve lifter wall 
Scratches/Damage 
and cylinder head. 



Replace both lifter 



Valve Installation 

1. Lubricate: 

• Valve stem 

• Oil seal 



5 



High-Quality Molybdenum Disulfide 
Motor Oil or Molybdenum Disulfide 
Grease 



2. Install: 

• Valve 

• Valve spring seat (2) 

• Oil seal (D 

• Valve springs (4) 

• Valve spring seat (5) 

• Valve retainers (6) 



NOTE: 

Install springs with wider-gapped coils facing 
upwards, as shown. 



(T) Larger pitch 
(2) Smaller pitch 



3-26 



ENG 


\» 




NSPECTDN AND 


REPAIR 








f J©L 




CAMSHAFT, CAM CHAIN, AND CAM 






SPROCKET 




/tIcHf 










3a f\\ 


1 . Inspect: 




~$B*h 


Q i 


• Cani bbes 




"^ W^r 


\\ 


Pithg/SciatEhes/felie discoloration --» 
Rephce. 
2 . M easuiE : 
• Cam bbes 




U se the M rimm eter. 

ut of specification -H R epace . 



% 




Cam Lobe 
"A" (Limit) 


Cam Lobe 
"B" (Limit) 


Intake 


36.15 mm 
(1.423 in) 


27.02 mm 
(1.064 in) 


Exhaust 


36.15 mm 
(1.423 in) 


27.02 mm 
(1.064 in) 



Camshaft/Cap Clearance Measurement 

1 . Install: 

*C am shaft 

2. Attach: 

• Plastigage® wv -33210) 

nto cam shaft. 

LA] For Exhaust 
[g For Intake 

3. Attach: 

*C am shaft cap pl-3" or <E-3") 
4 . Install: 

*C am shaft caps (others) 
5. Tijhten: 

*C am shaft cap bols 



CAttHOto 



First Tighten the Nos. 2,4, and 1 cap bote in 
that order, then the No . 3 cap bote ; otherw ise, 
the No. 3 caps may be damaged or bent. 



s 



Camshaft Cap: 

10 Nm (1.0m -kg, 7.2 ftlb) 



NOTE : 

Do not turn the camshaft when measuring 
clearance w ih P festgauge® . 



3-2 7 



INSPECTION AND REPAIR 




ENG 



\m 



6. Remove: 

• Camshaft caps 

7. Measure: 

• Width ofPlastigage® © 

Out of specification -> Followstep8. 




Camshaft-to-cap Clearance: 
Standard: 0.020 "0.054 mm 

(0.0008~ 0.0021 in) 
Maximum: 0.160mm (0.006 in) 



8. Measure: 

• Camshaft outside diameter 
Usea micrometer. 

u t of specification -* Replace camshaft. 
Within specification -* Replace cylinder 
head. 




Camshaft Outside Diameter: 

Standard: 24.967 " 24.980 mm 
(0.9830 "0.9835 in) 
Cam Cap Inside Diameter: 

Standard: 25.000~25.021 mm 
(0.9843-0.9851 in) 



Cam Chains 
1. Inspect: 
• Cam chains 
Chain stretch/Cracks 



Replace. 




Cam Sprockets 
1. Inspect: 
• Cam sprockets 
Wear/Damge -*■ Replace. 



Chain Dampers 
1. Inspect: 

• Upperdamper 

• Front damper (2) 

• Rear damper (f) 
Wear -* Replace. 



3-28 



ENG 


\» 



USPECTDN AND REPAIR 




/ | 













S*~\ 


^N 






D, 










o 7 






^ 


1 S 










L 




D|/ D 2 




J 




_ 








o 






°3 / D 4 






o 














^> 






D 5 /D 6 


- 




r-J 




















J 












Cam Cham Tensioner 

1. Check: 

• One-way| cam operation 
Unsmooth operation -H Replace. 

2. iispect: 
*AU. parts 

Damage/Wear ""* Replace. 



(4)| Tensioner body 
(Tj One way cam 
(fy Tensijner rod 



EndPhg 
W asher 

Spring 

CYL1DER 

1. Inspect: 
*Cy]inder wall. 

W ear/Scratches -h Reboie or repihce. 

2. Measuie: 

• Cyltnderl boie "C" 

Use the Cyihder Boie Gauge 
Out of specification -H Reboie. 



s 




Standard 


Wear Limit 


Cylinder 
Bore C: 


75.07 ~ 76.02 mm 
(2.756- 2.993 in) 


76. T mm 
(2.996 in) 


Cylinder 
Taper T: 


— 


0.05 mm 
(0.002 in) 


C a M axim urn D 

T a Maxim urn (D|]orD 2 ] 
— M iiin urn {D s or D*J 



PETON, PETON RIG, AND PETON PIN 

Piston 

1. Iispect: 
^Piston waH 

W ear^ cratnhes/t) am age -h Replace. 

2. Measuie: 

• Piston outsiie dimeter "P" 

Use a M room eter, 

Out of specification -H Replace. 






"■> 



3-29 



INSPECTION AND REPAIR 



ENG 


\m 



NOTE: 

Measurement should be made at a point 6.2 mm 
(0.244 in) above the bottom edge of the piston. 



s 




Size "P" 


<h^m^m 75.905 ~ 75.955 mm 
Standard (2.9884-2.9903 in) 


Oversize 1 
Oversize 2 


76.25 mm (3.002 in) 
76.50 mm (3.012 in) 



3. Measure: 

• Piston clearance 
Out of specification 
or replace piston. 



Rebore cylinder 




Piston Clearance = C — P: 
0.055 ~ 0.075 mm 
(0.0022 -0.0030 in) 



C: Cylinder bore P: Piston outside diameter 




Piston Ring 

1. Measure: 
• Side clearance 
Use the Feeler Gauge ® 
Out of specification -► 
and/or rings. 



Replace piston 





Side Clearance 


r^\i 


Standard 


Limit 


Top Ring 


0.03 -0.07 mm 
(0.0012 ~ 
0.0028 in) 


00.12 mm 

(0.0047 in) 


2nd Ring 


0.02 "0.06 mm 
(0.0008 ~ 
0.0024 in) 


0.12 mm 
(0.0047 in) 



3-30 



INSPECTION AND REPAIR 




2 . Position: 

• P Eton ring 
Into cylinder. 
Push the ring w ih the piston crown, 

3 . M easure : 

£* End gap 
Use the Feeier Gauge (T) . 
Out of specification -h Repb.ce rhgs as 
set. 



s 




End Gap 


Standard 


Limit 


Top Ring 


0.35 -0.50 mm 
(0.0138 - 

0.0197 in) 


0.75 mm 
(0.0295 in) 


2nd Ring 


035- 050 mm 
(0.0138 ~ 

0.0197 in) 


0.75 mm 
(0.0295 in) 


2~0Smm 
Oil Ring 0080.- - 
0.032 in) 



Oversie Piston Rings 

• The oversize top and m iidie ring sizes are 
stamped on top of the ring. 



Oveisdze 1 


25 mm (0.0098 ±i) 


Oveisie 2 


050 mm 0A197 ±i) 



*The expander spacer of the bottom rhg (oi 
control ring) is cobr-coded to identify sizes. 
The cobr m ark is painted on the expander 

spacer. 



Size 


Color 


Oversize 1 


Blue (Two) 


Oversize 2 


Red (One) 



Piston Pin 

1. Lubricate: 

*Piston pin (lightly) 
2 . install: 

• PEton ph 
Into sm all end of connecting rod. 



•"> 



3-31 



INSPECTION AND REPAIR 




ENG 



f~ 



3. Check: 

• Free play 

Free play -»■ Inspect connecting rod for 

wear. 

Wear -* Inspect connecting rod and piston 

pin. 

4. Position: 

• Piston pin 
Into piston. 

5. Check: 

• Free play 

When pin is in place in piston. 

Free play -* Replace piston pin and/or 

piston. 




STARTER DRIVES 

Electric Starter Clutch 

1 . Check: 

• Ball operation 
•Spring cap (2) operation 

• Spring (3) operation 

Unsmooth operation -* Replace one-way 
clutch. 



2. Check: 

• Damper housing (4) 



• Rubber dampers (D 
Cracks/Wear/Damage -» 

3. Install: 

• Rubber damper 

• Damper housing 
•One-way clutch 

4. Tighten: 

• Bolts (one-way clutch) 



Replace. 



ffl 



Bolts (Starter Oneway Clutch): 
24Nm(2.4m-kg, 17ft-lb) 
LOCTITE® 
Stake Over the End of the Bolt 



3-32 



ENG 



■,;;' 



INSPECTION AND REPAIR 




Starter Gears 

1. Inspect: 
• Idle gear surfaces 
Pi tting/Wear/Damage 



Replace. 



PRIMARY GEARS 

The drive gear is mounted on the crankshaft; 
the driven gear is mounted on the transmission 
and is intergrated with the clutch assembly. 
1. Inspect: 
•Drive gear 
Scratches/Wear/Damage -* Replace crank- 
shaft. 
•Driven gear © 
Scratches/Wear/Damage -»• Replace clutch 
housing assembly. 





nn 


Ijf 


n 


Xi/ri frWj 

V J / 


"TTIn \i 
L-sizi 




'aiuunnimni 


fflUP 




CLUTCH 
Clutch Housing 

1. Inspect: 
• Dogs on the housing 

Cracks/Wear/Damage -*■ Deburr or replace. 
•Clutch housing bearing 

Chafing/Wear/Damage ->• Replace. 



Clutch Boss 

The clutch boss contains a built-in damper 
beneath the friction plate © and clutch plate 
© . It is not necessary to remove the wire 
circlip © and disassemble the built-in damper 
unless there is serious clutch chattering. 



3-33 



INSPECTION AND REPAIR 




ENG 


\» 



1. Inspect: 
• Clutch boss splines 
Scoring/Wear/Damage 
boss assembly. 

NOTE: 



Replace clutch 



Scoring on the clutch plate splines will cause 
erratic operation. 



Friction Plates 

1. Inspect: 

• Friction plate (D 
Damage/Wear ->■ Replace friction plate as a 
set. 

2. Measure: 

o Friction plate thickness 
Measure at all four points. 
Out of specification -+ Replace friction 
plate as a set. 



m 



Wear Limit: 

2.8 mm (0.11 in) 




Clutch Plates 

1. Measure: 
• Clutch plate warpage 
Use the surface plate and the Feeler Gauge 

®. 

Out of specification -> Replace. 




Warp Limit: 

0.2 mm (0.008 in) 



Push Rod 

1. Measure: 
• Push rod runout (T) 
Use V-Blocks and the Dial Gauge 
(YU-03097). 
Out of specification -* Replace. 



Bending Limit: 
0.5 mm (0.02 in) 



3-34 



ENG 



n 



INSPECTION AND REPAIR 



Clutch Bearing 
1. Inspect: 

• Bearing 
Pitting/Damage 



Replace. 









^5v 


/xy / f 


-" \\^ 




^ 




sr^ 


— -\\w ^Xj^ ^^^- 




^© 



Clutch Spring 

1. Inspect: 

.Clutch spring (T) 
Wear/Bends/Cracks -> Replace. 

2. Measure: 

• Clutch springfree height (a) 
Out of specification -> Replace. 




Clutch Spring Minimum Height: 
6.5 mm (0.26 in) 



3. Measure: 

• Clutch spring warpage 

Use a surface plate and the Feeler Gauge (D , 
Out of specification ->■ Replace. 




Warp Limit: 

0.1 mm (0.004 in) 



Clutch Spring Seat 
1. Inspect: 
• Clutch spring seat (T) 
Wear/Bends/Damage ->- Replace, 



OIL PUMP 
1. Measure: 
• Housing (T) /Outer rotor (f) clearance (a) 



Use the Feeler Gauge. 
Out of specification 
assembly. 



Replace oil pump 




Side Clearance Limit: 
0.08 mm (0.0031 in) 



3-35 



INSPECTION AND REPAIR 




ENG 



%m 



2. Measure: 

• Outer rotor (j) /Inner rotor (2) clearance 

Usethe Feeler Gauge. 

Out of specification -y Replace oil pump 
assembly. 




Tip Clearance Limit: 
0.17 rnm (0.0067 in) 



OIL GALLERY PIPE 

1. Inspect: 
• 0-rings (j) 

Wear/Cracks/Damage -> Replace. 
•Gallery pipe (§) 
Cracks/Damage -* Replace. 



CRANKSHAFT 
Crankshaft 

1. Measure: 
• Runout 
Use the V-Blocks and Dial Gauge (J) 
(YU-03097). 
Out of specification -> Replace. 




Runout Limit: 

0.03 mm (0.0012 in) 



2. Inspect: 

• Crankshaft bearing surfaces 
Wear/Scratches -» Replace. 



Crankshaft Main Bearing Clearance Measurement 

1. Clean all parts. 

2. Position: 

.Crankcase half (upper) 
Place on a bench in an upside down posi- 
tion. 

3. Install: 

• Bearings 

Into the uppercrankcase. 

• Crankshaft 

3-36 



ENG \ m 



INSPECTION AND REPAIR 




4. Attach: 

• Plastigage® (YU-33210) 

Onto the crankshaft journal surface. 

NOTE: 

Do not turn the crankshaft until clearance 
measurement has been completed. 

5. Install: 

• Bearings 

Into lower crankcase. 

6. Tighten: 

• Bolts 

CAUTtON; 

Tighten to full torque in torque sequence as 
shown. 



© 



10 mm Bolts (Crankcase): 
40 Nm (4.0m-kg,29ft-lb) 



* With a washer 




7. Remove: 
•Bolts 

Reverse assembly order. 
•Crankcase (lower) 

Use care in removing. 

8. Measure: 

• Width of Plastigage®® 
Out of specification -» Replace bearings; 
replace crankshaft if necessary. 




Main Bearing Oil Clearance: 
0.020 "0.044 mm 
(0.0008~ 0.0017 in) 



3-37 



INSPECTION AND REPAIR 



ENG 







Connecting Rod Bearing Clearance Measurement 

1. Clean all parts. 

2. Install: 

"Connecting rod bearings 
Into connecting rod and cap. 

3. Attach: 

• Plastigage® (YU-33210) 
Onto the crank pin. 

4. Install: 
Connecting rod 
"Connecting rod cap 



NOTE: 

Be sure the letter on both components align to 
form perfect character. 

5. Lubricate: 

*Bolt threads (connecting rod) 



S 



Molybdenum Disulfide Grease 



6. Tighten: 

*Nuts (connecting rod cap) 



NOTE: 

Do not turn connecting rod until clearance 
measurement has been completed. 

CAUTION: 

Tighten to full torque specification without 
pausing. Apply continuous torque between 
3.0 and 3.8 m-kg. Once you reach 3.0 m-kg, 
DO NOT STOP TIGHTENING until final torque 
is reached. If tightening is interrupted between 
3.0 and 3.8 m-kg, loosen nut to less than 3.0 
m-kg and start again. 



ffl 



Connecting Rod Cap: 

36 Nm (3.6m-kg,25ft-lb) 



3-38 



ENG 



INSPECTION AND REPAIR 




7. Remove: 

• Connecting rod cap 
Use care in removing. 

8. Measure: 

• Width of Plastigage®© 

Out of specification ->■ Replace bearings 
and/or replace crankshaft if necessary. 




J4 J3 J2 Ji 






Connecting Rod Bearing Clearance: 
0.021 -0.045 mm 
(0.0008-0.0018 in) 



Crankshaft Main and Connecting Rod Bearing 
Selection 

• Numbers used to indicate crankshaft journal 
sizes are stamped on the crankweb. The first 
two (2) i A] are main bearingjournal numbers, 
starting with the left journal. The four (4) 
[B] rod bearing journal numbers follow in 
the same sequence. 



• The lower crankcase half is numbered J1, J2, 
J3, and J4 on the front left boss as shown. 



^N 




• The connecting rods are numbered 3 or 4. The 
numbers ® are stamped in ink on the rod. 



3-39 



INSPECTION AND REPAIR 




ENG 


%m 








Example 1: Selection of the crankshaft m ail 

bearings; 

• II the crankcase JQ-and crankshaft Jl sizes 

are No. 4 and No. 1, respectively, the beamg 
size No. is: 




B earing S ize N o . = 

'C rankcase N o . — C rankshaft No. = 

4 -1=3 (Brown) 




BEARING COLOR CODE 




No. 1 I Bine 




No. 2 I Bhck 




No. 3 


Brown 




No. 4 


G reen 




No. 5 


Yelbw 




No. 6 


Phk 




Example 2: Selection of the connecting rod 

bearing; 

• If the connecting rod PI and crankshaft PI 

sizes are No. 4 and No. 1, respectively, the 

bearhg size No. is: 




B earing S ize N o . = 

Connecting rod No. —Crankshaft No . = 

4-1 = 3 (Brown) 




BEARMG COLOR CODE 




No. 1 


Blue 




No. 2 


Black 




No. 3 


Brown 




No. 4 


Green 




No. 5 


Yellow 




No. 6 


Phk 




No. 7 


Red 



<~ 






BALANCER SHAFT 

Balancer ShaftBearing C learance M easurem ent 
1. Chan surfaces of bahncer shaft and crankcase 

pumal 
2 . Position: 

• C rankcase half (upper) 
Place on a bench in an upside down posi- 
tion. 



— I — — 

ENG % m 



INSPECTION AND REPAIR 




3. Install: 

• Bearings 

Intothe upper crankcase. 

4. Install: 

• Balancer shaft 
Intothe upper crankcase. 

5. Attach: 

• Plasticage® (YIK33210) 

Onto the balancer shaft journal surface. 



NOTE: 

Do not move balancer shaft until clearance 
measurement has been completed. 

6. Install: 

• Bearings 

Into lower crankcase. 

7. Tighten: 

• Bolts (crankcase) 

CAUTION: 

Tighten to full torque in torque sequence cast 
on the crankcase. 



ffl 



8 mm Bolt (Crankcase): 

24 Nm (2.4 m- kg, 9.6 ft- lb) 




8. Remove: 

• Bolts 

Reverse assembly order. 

• Crankcase (lower) 
Use care in removing. 

9. Measure: 

• Plastigage® width © 
Out of specification -> 



Replace bearings; 



replace balancer shaft in necessary. 




Balancer Shaft Bearing Oil Clearance: 
0.020" 0.048 mm 
(0.0008~ 0.002 in) 



3-41 



INSPECTION AND REPAIR 



ENG 



%m 




B a]ancer Shaft B earing Selection 
> Numbeis used to hdrate balancer shaft pumal 
sizes aiE stamped on the RH baincer web 
comer, starthg with the Deft journal 



(T| Left ba]ancer shaft: pumal size num ber 
(2j Right baiancer shaft journal size number 

• Thel lower crankcase half is num beied J5, and 

J6 as shown. 



lExample: Selection of the balancer shaft bear- 
ings; 
* IE the ciankcase J5 and left ba fence r shaft 

sizes a ie No. 4 and No. 1, respectively, the 

fet bahncer bearhg size No. is: 


Bearing Size No. = 

Crankcase No . —B alancer Shaft No . = 

4 —1 + 3 (Brown) 


BEARING COLOR CODE 


No. 1 


Blue 


No. 2 


Black 


No. 3 


Brown 


No. 4 


Green 


No. 5 


Yellow 


No. 6 




Pink 




TRANSM ESDN 
Shift Fork 

1 . inspect: 

• Shit folks 

O n the gear and shift cam contact sur- 
faces. 
W ear/Chafing/B ends/bam age -m Replace. 

2. Check: 

• Shit fork movement 
On is guide bar. 

Unsmooth operation -n Replace fork and/or 
guide bar. 



3A2 



ENG 



|<%J 



INSPECTION AND REPAIR 






r* 




■ 


: 
















1 « 


/ 


7^ 







Shift Cam 
1. Inspect: 

• Shift cam grooves 
Wear/Damage/Scratches -*■ Replace. 

• Shift cam segment 
Damage/Wear -> Replace. 

*Shift cam bearing 

Pitting/Damage -> Replace. 



Main and Drive Axles 

1. Measure: 
• Axle runout© 
Use the centering device and Dial Gauge 
(YU-03097) (2). 
Out of specification ->• Replace. 




Runout Limit: 0.08 mm (0.0031 in) 




Gears 

1. Inspect: 

• Gears 
Damage/Wear -*■ Replace. 

2. Check: 

• Gear movement 

Unsmooth operation -+ Replace. 

3. Inspect: 

• Mating dogs 
Cracks/Wear/Damage -> Replace. 

BEARINGS 
1. Inspect: 

• Axle bearings 

*S h if t cam bearing 
Pitting/Damage ■* Replace. 






CIRCLIPS AND WASHERS 
1. Inspect: 

• Circlips 

• Washers 
Damage/Looseness/Bends 



Replace. 



3-43 



MIDDLE GEAR SERVICE 



ENG 



*: 



MIDDLE GEAR SERVICE 



©Universal joint 
(2) Dust seal 
©Housing 
©O-ring 

©Bearing 
@Collapsible collar 
©Bearing 
@Middle drive shaft 
@Middle driven pinion gear 
@ Spring seat 
<0) Damper spring 
© Damper cam 



@Middle drive pinion gear 
(H) Thrust washer 
(Q) Retainer 



90 Nm O.Om-kg, 65fr lb) 



30 Mm (3.0m-kg, 22 ft- lb) 





SHIMS: 




0.10 mm (0.004 in) 


A 


0.15 mm (0.006 in) 




0.30 mm (0.012 in) 




Always use a new one 



GEAR LASH: 
0.05-0.12 mm 
(0.002 -0.005 in) 



if 





SHIMS: 




0.15 mm (0.006 in) 


A 


0.30 mm (0.012 in) 




0.40 mm (0.016 in) 




0.50 mm (0.020 in) 



IIONm (11.0m-kg, 80 ft-lb) 

STAKE 



3-44 



ENG 



# 



MIDDLE GEAR SERVICE 



(T) Drive axle 

(2) Drive pinion gear shim 

S Bearing 
Middle drive pinion gear 
(D Collapsible collar 

(Always use a new one) 

® Spacer 

(7) Middle driven pinion gear 

(8) O-ring 

(D Universaljoint 



@ Oil seal 

(Jj) Bearing retainer 

@ Bearing housing 

(J|) Driven pinion gear shim 

(R) Nut (drive pinion gear) 

{jj) Nut (driven pinion gear) 

©Bearing stopper 



E STAKE 



[A] STAKE 



IIONm 

(11.0m- kg, 80 ft- lb) 




25 Nm (2.5 m-kg, 18 ft- lb) 






IE 



s ■*= 



-r~x 



^L^CX 



0.05-0.12 mm 
(0.002 ~ 0.005 in) 




*"> 



^ 



30 Nm {3.0m-kg,22ff lb) 



90 Nm (9.0 m-kg, 65 ft- lb) 



^ 



C' STARTING TORQUE: 



0.4-0.5 Nm {0.04 ~ 0.5 m-kg, 
0.28- 0.35ft- lb) 



3-45 



MIDDLE GEAR SERVICE 



ENG 



DRIVE AXLE POSITIONING 

When the crankcase assembly and/or the drive 

axle are replaced, you must position the drive 

axle in place. 

Refer to "Drive Pinion Gear Shim Selection and 

Middle Gear Lash Adjustment" section. 

(T) Drive pinion gear 

(2) Driven pinion gear 

[A"| Drive pinion gear shim 

\& Driven pinion gear shim 





Drive Pinion Gear Shim Selection 
• "A" = 54.5 plus or minus the numberstamped 
on the drive pinion gear. 



• " B" = 53 plus the number stamped on the left- 
side rear of the upper crankcase. 



3-46 



ENG \m 



MDDLE GEAR SERVEE 



lExample: Selection of the drive pinion gear 
ishin ; 



!shin Thickness = 

[Distance "A" — Distance "B' 



<H If the drive pinion gear is stamped '03" (plis 
(+ 03) is in pled heie since on^ the m iius 
(-) designations aie stam ped alongside the 
numbers), then: 
A" =53-0 .03 
= 54.53 

INOTE: 

j Ail stam ped numbers aie in hundredths of a 



• ■ If the left-side-rear of the upper crankcase 
is stamped "95", then: 
"B'1= 53 + 0.95 

= 53.95 
Therefore : 
T = A -B 

=i 5453 _ 53.95 
= 0S8 mm 
'•The calculated shin thickness is 58 mm . 
Because shin can on^ be selected in 0.05 
mm increments, use the folbwiig chart to 
round off the hundredths digtof the calcu- 
lated thickness and selest the approprkte 
shim , 



Hundredths Digit 



0,1,2 



3, 4, 5, 6 



7,8,9 



Rounded Value 



10 



1 'Using) the above example, the calculated 
shin thickness of 58 mm is rounded off to 

.60 m m . Therefore , you m ay choose either 
4 — 015mm shin s , 2 — 030mm shins,or 

1 — 0.3 mm and 2 — 0.15 mm shins as 
selected from the shin thickness chart 
below . Shin size are suppled ii the folbw- 
iig thhknesses: 




347 



MIDDLE GEAR SERVICE 



ENG 



^^ 




Middle Gear Lash Adjustment 

1. Attach: 

• Middle Drive Gear HolderCD (YM-33222) 
This tool will prevent the drive axle from 
turning. 

2. Install: 

• Bolts (three) 

On driven bearing housing. 
Finger-tighten the bolts. 

NOTE: 

Clearance between the crankcaseand driven bear- 
ing housing should be about 2 mm. 
Measure gap with Feeler Gauge @ . 

3. Position: 

• Dial Gauge® (YU-03097) 
On the outside edge of U-joint. 

NOTE: 

Be sure the gauge is positioned over the center- 
line of the yoke bearing hole. 

4. Rotate: 

• U-joint 

Move it gently back and forth. 

5. Measure: 

• Gear lash 

Over specification -* Follow next steps. 
Under or same specification -> Incorrect; 
check for faulty parts and/or reassemble 
bearing housing. 



S 



Middle Gear Lash: 
0.05 ~ 0.12 mm (0.002 " 0.005 in) 



CAUTION: 



Do not hammer the U-joint or the collapsible 
collar of the driven pinion gear may bedistorted. 
This will result in a change in the standard start- 
ing torque, requiring replacement of the col- 
lapsible collar and reassembly of the driven gear 
assembly. 



NOTE: 

Check the gear lash at four positions. Rotate the 
U-joint 90 degrees each time and repeat the 
gear lash check. 



3-48 



ENG 



4fl 



MIDDLE GEAR SERVICE 



6. Tighten: 
• Bolt (Three) 
Tighten carefully one-thread turn only. Push 
in bearing housing and hold in position 
while tightening bearing housing bolts. 



CAUTION: 



Do not overtighten bearing housing bolts or you 
may obtain too little gear lash and cause damage 
to gears. If over tightened, loosen the 3 bolts so 
that crankcase/bearing housing clearance is 
about 2 mm (0.08 in) and repeat all previous 
steps. 

7. Repeat steps 4 and 5 until correct gear lash 
is achieved. 




Middle Gear Lash: 

0.05 ~ 0.12 mm (0.002 ~ 0.005 in) 




8. Measure: 

• Crankcase/bearing housing clearance 
Use a Feeler Gauge. 

9. Select: 

• Shim(s)(D 

By the following steps. 



3-49 



Example: Selection of the driven pinion gear 
shim; 

• If the clearance is 0.46 mm. 

• The shim can only be selected in 0.05 mm 
increments, round off hundredths digit and 
select appropriate shim{s). 


Hundredths 


Round Value 


0. 1,2 





3.4. 5,6 


5 


7,8,9 


10 


• In the example above, the measured shim 
thickness is 0.46 mm. The chart instructs 
you, however, to round off the 6 to 5. Thus 
you should use 0.15 mm and 0.30 mm 
shims. 

• Shim sizes are supplied in the following 
thickness. 


g 




Driven Pinion Gear Shim 


Thickness (mm) 


0.10 0.15 0.30 
n„n 0.50 0.60 



•^ 



^ 



*> 



MIDDLE GEAR SERVICE 




ENG 



\m 



10. Tighten: 

• Bolts (bearing housing) 




Bolts (Bearing Housing): 
30 Nm (3. On- kg, 22 ft- lb) 



NOTE: 

Before tightening the bolts, make sure that the 
arrow on the bearing housing points to the upper 
crankcase. 

1 1 . Measure: 
• Gear lash 




REMOVAL 

1. Remove: 
• Drive axle assembly ® 



2. Attach: 

• Damper Spring Plate (YM-33286) 

• Middle Drive Gear Holder (YM-33222) (2) 
Onto drive pinion. 

3. Position: 

• Drive axle shaft assembly 
Onto a Hydraulic Press. 

4. Compress the damper spring on the drive 
axle shaft assembly. 

5. Remove: 

• Retainers ® 
« Washer (2) 

• Drive pinion gear d) 

• Damper cam ® 

• Damper spring (5) 

• Spring seat (D 

• Bearing (7) 



3-50 



ENG 



*^ 



MIDDLE GEAR SERVICE 




6. Remove: 

• Nut (drive gear) 

Use the Offset Wrench (D (YM-04054). 

• Bearing 

• Shim(s) 





INSPECTION 

1. Inspect: 

• Damper cam surfaces 

Wear/Scratches -> Replace damper and drive 
pinion gear as a set. 

2. Inspect: 

• Damper spring 
Damage/Cracks ->• Replace. 





ASSEMBLY 
1. Install: 

• Shim(s) 

• Bearing 

• Nut (drive gear) 

Use the Offset Wrench (D (YM-04054). 



£J 



110 Nm (11m- kg, 80 ft-lb) 
LOCTITE® 



2. Lock the threads with center punch (T) as 
shown. 



3. install: 

• Bearing© 

• Spring seat (2) 

• Damper spring (§) 

• Damper cam © 

• Drive gear assembly (D 

• Washer (6) 



^ 



3-51 



MIDDLE GEAR SERVICE 




ENG 


\m 



4. Attach: 

• Damper Spring Plate (YM-33286) <£) 

• Middle Drive Gear Holder (YM-33222)(2) 

5. Position: 

• Drive axle shaft assembly 
Onto a Hydraulic Press. 

6. Compress the damper spring on the drive 
axle assembly. 

7. Install: 

• Retainers 

Into drive axle shaft groove. 

• Drive axle shaft assembly 
Onto the crankcase. 



MIDDLE DRIVEN GEAR BEARINGS 

The following procedures should be performed 
only if the middle driven gear or middle drive 
shaft bearing(s) must be replaced. 




Universal Joint Removal 
1. Remove: 
• Universal joint 
By the following. 



iiZW=j — 




mm 


j~Z~E2I^ 






\ ® 


^ --_J i 





Universal joint removal steps: 

• Remove the circlips®. 

• Place the U-joint in a press. 

• With a suitable diameter pipe beneath the 
yoke, press the bearing into the pipe as 
shown. 

NOTE: 



It may be necessary to lightly tap the yoke 
with a punch. 



• Repeat the steps for the opposite bearing. 

• Remove the yoke. 

NOTE: 



It may be necessary to lightly tap the yoke 
with a punch. 



Attach: 

• Universal Joint Holder® (YM-04062) 
Onto the universal joint yoke. 



3-52 



ENG 




MIDDLE GEAR SERVICE 



3. Remove: 

• Nut (driven pinion gear) 

• Washer 
*Yoke 

• Bearing 

• Bearing housing 
*Collapsible collar 

• Spacer 

Inspection 

1. Inspect: 

• Gear teeth 

Pitting/Galling/Wear -> Replace middle gear 
as a set. 

• Bearings 
Pitting/Damage^- Replace. 

2. Check: 

• U-joint movement 
Roughness -» Replace U-joint. 




Assembly 
1. Install: 
• Bearing outer race 
Into the bearing housing. 

CAUTION: 



Do not press the bearing outer race. Always 
press the inner racewith care when installing. 

2. Install: 

• Inner bearing 
*S pacer (f) 

.Collapsible collar (3) (new) 

• Bearing housing (?) 

• Outer bearing (5) 

• Dust seal (6) 
*Yoke (7) 

• Washer (§) 

• Nut (driven pinion gear)(D 

3. Attach: 

• Universal Joint Holder (YM-04062) 
Onto the universal joint yoke. 

4. Tighten: 

• Nut (driven pinion gear) 

Torque nut carefully, little by little. 



m 



Nut (Driven Finion Gear): 
90 Nm (9.0 m -kg, 65 ft- lb) 
LOCTITE® 



3-53 



MIDDLE GEAR SERVICE 




ENG 



%m 



5. Measure: 
*Starting torque (driven pinion gear) 
Under specification -* Repeat steps from 4. 



£ 


Starting Torque (Driven Pinion Gear):: 
0.4 ~ 0.5 Nm (0.04- 0.05 rrv kg, 


0.29- 0.36ft- lb) 




CAUTION; 



• Never exceed the standard starting torque. 

*Be sure to tighten the driven pinion gear nut 
slowly, carefully checking measurements each 
time. Exceeding the standard starting torque 
may depress the collapsible collar, requiring 
reassembly. 

• To reassemble, you must replace the collapsible 
collar and repeat the steps in 4 and 5 to obtain 
the standard starting torque. 




6. Position: 

• Yoke 
Intothe U-joint. 

7. Lubricate: 

• Bearings 



IM 



Wheel Bearing Grease 



8. Install: 
• Bearings 
Onto the yoke. 



CAUTION: 



Check each bearing. The needles can easily fall 
out of their races. Slide the yoke back and forth 
on the bearings; the yoke will notgoalltheway 
onto a bearing if a needle is out of palce. 

9. Press each bearing into U-joint using a 
suitable socket. 



NOTE: 

Bearing must be inserted far enough into U- 
joint so that circlip can be installed. 

10. Install: 
• Circlips (D 
Into groove of each bearing. 



3-54 



ENG 


^m 




ENGINE ASSEMBLY AND ADJUSTMENT 

ENGINE ASSEMBLY AND 
ADJUSTMENT 

LOWER CRANKCASE 
1. Install: 

• Oil pump idle gear (2) 

• Circlipd) 



2. Install: 

• Shift cam 

• Shift forks (No. 1,2,3) 

• Guide bars 

NOTE: 



All numbers should face the left side and be in 
sequence (1,2 3), beginingfrom the left. 



3. Install: 

• Bearing retainer (shift cam) 
4. Tighten: 

• Screws (bearing retainer) 



fj 



Screws (Bearing Retainer): 
LOCTITE® 
7Nm (0.7 m- kg, 5.1 ft- lb) 




5. Rotate the shift cam to neutral position. 

6. Install: 

• Shift cam stopper lever (T) 

• Tension spring (5) 

• Washer® 

• Bolt (shift cam stopper lever)® 

7. Tighten: 

• Bolt (shift cam stopper lever) 



© 



Bolt (Shift Cam Stopper Lever"): 
8 Nm (0.8m -kg, 5.8 ft- lb) 
LOCTITE® 



NOTE: 

Check for smooth operation after tightening the 
stopper lever. 



3-55 



ENGINE ASSEMBLY AND ADJUSTMENT 



CRANKSHAFT/CONNECTING ROD/PISTON 

(T) Piston ring 

(2) "Y" mark 

(f) Matching mark 

(A) Connecting rod bearing size 

(5) Projection 

(6) Washer 

(7) Journal bearing size 
(?) Crank pin size 

(9) Balancer matching mark 



ENG \p 



© 



PISTON TO CYLINDER CLEARANCE: 
0.055 - 0.075 mm (0.0022 - 0.0030 in} 




B 


END GAP LIMIT: 


C 


Top: 0.75 mm {0.0295 in) 


D 


2nd: 0.75 mm (0.0295 in) 



CONNECTING ROD 
BEARING CLEARANCE: 
0.021 ~ 0.045 mm 
{0.0008-0.0018 in) 



CRANKSHAFT JOURNAL 
CLEARANCE: 
0,020 - 0.044 mm 
(0.0008-0.001 7 in} 



[§] #2 CYLINDER 



— © M #4CYLINDER ® 



130 Nm (13.0 m -kg, 94 ft- lb) 




1U #1 CYLINDER 



[J #3 CYLINDER 



3-56 



ENG \ m 



ENGINE ASSEMBLY AND ADJUSTMENT 



TRANSMISSION 

(T) Circlip 

(2) Bearing 

(3) 1stwheelgear(43T) 
© 4th wheel gear (28T) 
(D Circlip 

(6) Washer 

(7) 3rd wheel gear (3 1T) 
(§) Drive axle 

® Plug 



© 2nd wheel gear (39T) 

(jj) Washer 

©Circlip 

(0) 5th wheel gear (26T) 

(Q) Bearing 

©Bearing 

SMain axle 
4th pinion gear (26T) 
©Washer 



©Circlip 

#2nd, 3rd pinion gear (22/23T) 

@5th pinion gear (28T) 

©Washer 

@Circlip 

@ Bearing 

@Circlip 



DEFLECTION LIMIT: 
0.08 mm (0.0031 in) 




3-57 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



Xm 




8. Install: 

• Shift shaft assembly 



(T) Shift lever 1 
(2) Shift lever 2 

TRANSMISSION 

1. Install: 
• Plane bearings (crankshaft/balancer shaft) 



NOTE: . 

Identify each plane bearing position very carfuly 
so that it can be reinstalled in its original palce. 




2. Install: 

*Main axle assembly (T) 
• Drive axle assembly @ 

NOTE: 



• Insert the bearing circlips (3) completely into 
lower crankcase positioning grooves. 

• Position the bearing pin (4) as shown. 



3. Install: 

• Middle driven pinion gear assembly ® 

NOTE: 

• Be careful not to damage the 0-ring(2) during 
installation. 

• The arrow mark (D on the bearing housing 
points to the upper crankcase. 



4. Install: 

• Push rod support bearing (f) 



NOTE: 

• Insert the bearing pin (2) into the crankcase 
hole. 

• Position the oil seal (3) snugly against the 
bearing. 

• Lightly apply grease to the oil seal lips. 



3-58 



ENG 


'<!• 



ENGINE ASSEMBLY AND ADJUSTMENT 




5. Check: 

transmission and shifter operation 
Unsmooth operation -> Repair. 

NOTE: 



Oil each gear and bearing thoroughly. 

6. Install: 

*Crankshaft with cam chains © 
• Balancer shaft (D 

NOTE: 



Align the mark (3) on the balancer shaft gear 
with the mark® on the cranks haft gear. 



UPPER CRANKCASE 

1. Install: 
• Plane bearings {crankshaft/balancer gear) 

NOTE: 

Identify each plane bearing position very carefuly 
so that it can be reinstalled in its original place. 




®Vi 


-^/® 


I 25 ° \ 


/ 25° \ 


1 25° J 


\ 25 ° / 


®' 


"V® 



2. Install: 
• Piston rings 
NOTE: 



Be sure to install rings so that Manufacturer's 
marks or numbers are located on the top side of 
the rings. 

3. Oil liberally: 

• Pistons 

• Rings 

• Cylinders 

4. Set: 

• Piston ring ends 



CAUTION: 



Make sure the ends of the oil ring expanders do 
not overlap. 

© TOP (2) OIL RING (LOWER RAIL) 
©OIL RING (UPPER RAIL) ©2ND 



3-59 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 




®i ® 




5. Install: 
*Piston (D 

• Piston pin (2) 

• Piston pin clip0 



NOTE: 

• Be sure the piston is positioned correctly as 

shown. 
*Always install new piston pin clips. 

• Plane bearings (connecting rods) (7) 
Onto the connecting rod and cap. 



(4) "Y" Mark 

(5) "EX" Exhaust side 

(6) "IN" Intake side 
(J) Projection 

6. Install: 
• Piston/Connecting rod assembly (#1 ~ #4) 
Into the upper crankcase. 
By the following steps. 



Piston/Connecting rod assembly installation 
steps: 

• Attach the Piston Ring Compressor® (YM- 
8037) to the piston. 

• Install the piston to the cylinder. 



NOTE: 

• The stamped "Y" mark (2) on the No. 2 and 
No. 4 connecting rods should face towards 
the RIGHT side of the crankcase. 

• The stamped "Y" mark (2) on the No. 1 and 
No. 3 connecting rods should face towards 
the LEFT side of the crankcase. 



E Top view 

(D Front 

(4) "Y"-mark facing direction 

(5) Piston exhaust mark 

(6) Piston intake mark 



3-60 



ENG 




ENGINE ASSEMBLY AND ADJUSTMENT 




CRANKCASE ASSEMBLY 
1. Apply: 
• Sealant (Quick Gasket@) 
(ACC-1 1001-05-01) 
To the mating surfaces of both case halves. 



NOTE: 

DO NOT ALLOW any sealant to come in contact 
with the oil gallery O-ring, or crankshaft bear- 
ings. Do not apply sealant to within 2 ~ 3 mm 
(0.08~ 0.12 in) of the bearings. 



2. Set shift cam and transmission 
NEUTRAL position. 

3. Install: 

• Upper crankcase 

• Dowel pins 

To the lower crankcase. 

NOTE: 



gears in 



Attach a length of wire to each cam chain and 
place cam chains on timing gear sprockets. 



CAUTION J 




Before tightening the crankcase bolts, check the 
following points: 

• Be sure the gear shifts correctly while hand- 
turning the shift cam. 

• Be sure the balancer shaft gear is aligned so that 
the dot mark lines up between the triangular 
timing marks on the upper crankcase when 
the No. 1 piston is at TDC. 

(D Balancer shaft mark 
(2) Triangular timing marks 

4. Finger-tighten the several crankcase bolts, 
preferably wide apart. Then, turn the crank- 
case assembly upside down. 



NOTE: 

Be careful not to let pistons fall out of the 
cylinders. 

5. Install: 
• Rod caps 



NOTE: 

Be sure the letters on both components align 
to form a perfect character. 



3-61 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



Us 




6. Tighten: 

• Nuts (connecting rod cap) 



ffl 



Nut (Connecting Rod): 
36 Nm (3. 6m kg, 25 ft- lb) 



NOTE: 

• Apply Molybdenum disulfide grease to the rod 
cap bolt threads and nut surfaces. 

• The projection ® on the connecting rod cap 
should faces the crankshaft web. 



CAUTION: 



^ 



r* 




When tightening the rod cap, apply continuous 
torque between 3.0 and 3.8 nvkg. Once you 
reach 3.0 nvkg of torque, DO NOT STOP 
TIGHTENING until final torque is reached. If 
tightening is interrupted between 3.0 and 3.8 
nvkg, loosen the nut to less than 3.0 nvkg, 
and start again. Tighten to full-torque specifi- 
cation without pausing. 

7. Tighten: 

• Bolts (crankcase) 

NOTE: 

Tighten the bolts starting with the lowest 
numbered one. 

•* With washer 
□ LOWERCASE 
HI UPPERCASE 



6 


6 mm Bolt: 

12 Nm (1.2 m -kg, 8.7 ft- lb) 

8 mm Bolt: 

24 Nm (2.4m- kg, 17ft-lb) 

10 mm Bolt: 
40 Nm (4.0 m- kg, 29 ft- lb) 





NOTE: 

• Install the oil pipe bracket on Bolt Nos. 1 and 
3. 

• Install the lead wire bracket on Bolt No. 22. 

• Install the battery ground lead on Bolt No. 36. 

• Install the copper washers on Bolt Nos. 28 and 
30. 



3-62 



ENG 



# 



ENGINE ASSEMBLY AND ADJUSTMENT 




8. Check: 

• Crankshaft operation 
Unsmooth operation ->• Repair. 

9. Install: 

• Bolts (middle driven gear housing) 



NOTE: 

The arrow mark ® on the bearing housing 
points to the upper crankcase. 

10. Install: 

• Retainer (main axle bearing)® 

NOTE: 

Be sure that the groove in the shaft mesh with 
the slot in the retainer. 



ffl 



Retainer (Main Axle Bearing): 
7 Nm (0.7 m- kg, 5.1 ft- lb) 
LOCTITE® 



11. Install: 

• Retainers (middlegear bearing)® 
Use the #40 Torx Drive (YU-29843-7). 
Stake screw head with center punch to 
lock. 



£1 



Retainers (Middle Gear Bearing): 
25 Nm (2.5m- kg, 18 ft- lb) 



OIL PUMP AND OIL PAN 
1. Install: 

• Damper (oil pump pipe) ® 

• Oil pump pipe® 



-"> 



3-63 



r- 



ENGINE ASSEMBLY AND ADJUSTMENT 




ENG 



\m 



2. Install: 

o Main oil gallery pipe © 
• Oil pipe (2) 

NOTE: 



Make sure the correct 0-rings(3) are installed on 
gallery pipe. 



3. Tighten: 
• Bolts (main oil gallery pipe)© ,(2) 



£J 






6 mm Flange Bolt ® : 

12 Nm (1.2 m- kg, 8.7 ft- lb) 

8 mm Union Bolt® : 

18 Nm (1.8 m- kg, 14 ft- lb) 



4. Bend the bracket tabs (f) 



5. Install: 

• Dowel pins 

• Oil pump assembly 

NOTE: 

• Make sure the correct O-ring © is installed on 
oil pump pipe. 

• The arrow mark (2) on the oil pump should 
face toward the rear. 



£J 



Oil Pump: 

10 Nm (1.0 m- kg, 7.2 ft- lb) 




6. Install: 

• Gasket 

• Dowel pins 

• Oil pan© 



m 



Oil Pan: 

10Nm(1.0m-kg,7.2ft-lb) 



7. Clamp the oil level gauge lead. 



3-64 



ENG 



*m 



ENGJNE ASSEMBLY AND ADJUSTMENT 




8. Install: 

• Oil filter cover (T) 



NOTE: 



Be sure that the projections (2) on the filter 
cover mesh with the slots (f) on the crankcase. 




Oil Filter Cover: 

32Nrn (3.2 m- kg, 23 ft- lb) 



BREATHER COVER AND STARTER MOTOR 

1. Install: 

• Oil pipe® 

• Breather cover spacer (§) 

• Breather cover 



fH 



Bolt (Breather Cover): 

10Nrn (1.0 m- kg, 7.2 ft- lb) 



(2) O-ring 

2. Install: 

*Starter motor (f) 



fl 



Bolts (Starter Motor) : 

10 Nm (1.0rn-kg, 7.2 ft- lb) 




WATER PUMP AND THERMOSTATIC VALVE 

1. Install: 
• Thermostat assembly (T) 





Thermostatic Valve Housing: 
10IMm (1.0m- kg, 7.2 ft- lb) 



Water Pump Case and Housing: 
10 Nm (1.0 m- kg, 7.2 ft- lb) 



3-65 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



%B 




2 

w 


ill 


4 




CLUTCH AND OIL PUMP DRIVE GEAR 

1. Install: 

• Oil pump drive gear ® 

• Circlip (D 



2. Install: 

• Clutch housing (T) 

• Thrust washer (2) 

• Clutch boss(D 

o Lock washer (new)® 

• Nut (clutch boss) ® 



3. Tighten: 

• Nut (clutch boss)® 
Use the Clutch Holder (YM-91042) ® to 
hold the clutch boss. 



£1 



Nut (Clutch Boss): 

70 Nm (7.0m- kg, 50fMb) 



4. Bend the lock washer tabs along the nut flat. 

5. Install: 

• Push rod® 

• Friction plates® ,® 

• Clutch plates® 

NOTE: 

Install the friction plates and clutch plates 
alternately on the clutch boss, starting with a 
friction plate and ending with a friction plate. 

By the following installation steps. 



3-66 



ENG 


\m 



ENGINE ASSEMBLY AND ADJUSTMENT 



CLUTCH AND OIL PUMP DRIVE GEAR 



(T)Washer 

@Clutch spring 

©Spring seat 

©Pressure plate 

©Friction plate (2 pes) 

©Clutch plate (7 pes) 

©Friction plate (6 pes) 

©Bearing 

©Push rod (No. 1) 

©O-ring 



(Q) Ball 

©Push rod (No. 2) 

(f§)Circlip 

(U)Spring washer 

©Clutch boss 

©Thrust washer 

©Clutch housing 

©Collar 

©Oil pump drive gear (36T) 

©Main axle 



@0-ring 

@ Dowel pin 

©Oil pump 

fyjO\ pump driven gear (32T) 



FRICTION PLATE THICKNESS: 



WEAR LIMIT: 2.8 mm (0.1 1 in) 



CLUTCH PLATE WARP LIMIT: 
0.2mm (0.008 in)) 



CLUTCH SPRING MINIMUM HEIGHT: 



6.5 mm (0.26 in) 



CLUTCH SPRING WARP LIMIT: 
0.1 mm (0.004 in) 



8 Nm (0.8 m-kg, 5.8 ft-lb) 




70 Nm (7.0 m-kg. 



25 Nm (2.5 m-kg, 18 ft-lb) 



3-67 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



*U 




Friction plates and clutch plates installation 

steps: 

■ Install the six friction plates (with the 

double semi-circular slots) and the six 

clutch plates. 



NOTE: 

Be sure the double semi-circular slots © on 
the friction plate is aligned with the clutch 
housing embossed match marks® . 



» Install the clutch plate and the friction plate 
(with the wide square slot). 



NOTE: 

Be sure the wide square slot (3) on the friction 
plate is aligned with the clutch housing 
embossed match marks (2) . 



• If the clutch does not release due to hard 
meshing between the friction plates and the 
clutch housing, check to see if any of the 
friction plates fit too snugly into the clutch 
housing. Any tight-fitting friction plates 
must be repositioned as follows. 

1) Remove the friction plates and the clutch 
plates. 

2) Install the six friction plate (with the 
double semi-circular slots) and the six 
clutch plates. 



NOTE: 

» Invert the friction plates. 

• Be sure the single semi-circular slot (4) on 
the friction plate is aligned with the clutch 
housing embossed match marks (2) . 
3) Install 'the clutch plate and the friction 
plate (with the wide square slot). 



NOTE: 

• Invert the friction plates. 

• Be sure the narrow square slot (X on the 
friction plate is aligned with the clutch 
housing embossed match marks® . 



3-68 



ENG 



\m 



ENGINE ASSEMBLY AND ADJUSTMENT 




6. Install: 

o Pressure plate 



NOTE: 




















Be sure 


the ma 


tch 


mark 


© 


on 


the 


clu 


tch 


boss 


is aligned with 


th 


e ma 


tch 


ma 


rk 


<D 


on 


the 


pressure 


plate. 



















7. Install: 
oSpring seat 
oClutch spring 

• Plate washer 

• Bolts (clutch spring) 



ffl 



Bolt (Clutch Spring): 

8IMm (0.8 m- kg, 5.8 ft- lb) 




8. Install: 

• Dowel pins 
oGasket 

• Crankcase cover (right) (D 
NOTE: 



Tighten the bolts in a crisscross pattern. 



m 



Crankcase Cover (Right): 
10Nm (1.0 m- kg, 7.2 ft- lb) 



^ 




FLYWHEEL AND STARTER IDLE GEAR 

1. Install: 
oOil baffle plate ® 



& 



Oil Baffle Plate: 

7Nm (0.7 m- kg, 5.1 ft- lb) 



3-69 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


Xm 




i_ X JL£ 




2. Install: 

• Starter clutch gear 

• Woodruff key 

CAUTION; 



Be sure to remove any oil and or grease from the 
tapered portion of the crankshaft and rotor with 
a thinner. 



3. Install: 
• Flywheel 



NOTE: 

When installing the flywheel, do not allow the 
oil baffle plate to touch the projections 
on the flywheel. 



4. Install: 

• Pin0 

• Plain washer 

• Bolt (flywheel) 



NOTE: 

Check for clot of oil passage in the bolt. 
If any, clean the oil passage. 



ffl 



Bolt (Flywheel): 

130Nm (1 3.0 nv kg, 94 ft- lb) 



5. Install: 

• Starter idle gears 



6. Install: 

• Dowel pins 

• Gasket 

• Crankcase cover (left) 
NOTE: 



Tighten the bolts in a crisscross pattern. 



ffl 



Crankcase Cover (Left): 

10 Nm (1.0 m- kg. 7.2 ft- lb) 



3-70 



ENG 



ENGJNE ASSEMBLY AND ADJUSTMENT 




CYLINDER HEAD AND CAMSHAFT 
Rear Cylinder Head 

1. Install: 

• Dowel pins® 

• Gasket (£) 

• Rear cam chain guide (?) 

NOTE: 



• The gasket "HEAD" mark (3) should the 
upward. 

• The lower end of chain guide must rest in the 
cam chain guide slot in the crankcase. 

• Cylinder head 

Pass cam chain through cam chain cavity. 
2. Install: 

• Nuts (cylinder head) 

Use 8 mm Wrench Adapter (YM-28897). 

NOTE: 

• In sequence as shown and torque nuts in two 
stages. 

• Never lubricate the bolt threads with engine 
oil. 



£3 



Nuts (Cylinder Head): 
43 Nm (4.3m- kg, 31 ft- lb) 






^ 




3. Install: 

• Water jacket joints (j) 

NOTE: 



Be sure each joint passes through its correspond- 
ing cam chain. 



• Lock pin (3) 

(Do-ring 



^ 



^ 



3-71 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



m 



CYLINDER HEAD AND CAMSHAFT 



(T) Washer 

(2) Rubber washer 

(D Pad 

(4) Valve lifter 

(5) Valve retainer 
(D Spring seat 
(7) Inner spring 
(f) Outer spring 
(9) Spring seat 



(fig! Oil seal 
(fi) Valve 
(fj) Gasket 
(f§>Sprak plug 
©Joint 
© O-ring 
©Oil plug 
@Valve guide 
(jJ)Circlip 



lONrn (1.0 m-kg, 7.2 ft- lb) 




10 Nm (1.0 m-kg, 7.2 fflb) 



A 


VALVE CLEARANCE (COLD): 


B 


Intake: 


0.11 ~ 0.15mm 
(0.004 ~ 0.006 in) 


C 


Exhaust: 


0.26 ~ 0.30 mm 
(0.010 ~ 0.0012 in) 






D 


TYPE/GAP: 




DPR8EA-9/NGK 
X24EPR-U9/NIPPONDENSO 




0.8 ~ 0.9 mm (0.031 ~ 0.035 in) 





43 Nm (4.3 m-kg, 31 fflb) 





(1.75 m-kg, 12.5 ft- lb) | 



-<P 



15 Nm (1.5 m-kg, 11 fflb) 



CYLINDER HEADWARP LIMIT: 
0.03 mm (0.0012 in) 




3-72 



ENG 



\m 



ENGINE ASSEMBLY AND ADJUSTMENT 





4. Install: 
• Camshafts 
By the following installation steps. 



Camshaft installation steps : 

• Align the "T-1" mark (D on the flywheel 
with the stationary pointer (2) on the crank- 
case cover use 32 mm wrench. 

CAUTION: 

1 Never turn the flywheel installing bolt. 
Rotating the bolt may loosen it, causing 
the rotor to fall out. 

» Do not turn the crankshaft during the cam- 
shafts installation. 



» Install the cam chain sprockets onto the 
camshafts. 



VOTE: 

Make sure the "REAR" mark (D on the cam 
:hain sprockets face away from the "IN" 
nark (4) and "EX" mark (§) on the camshafts. 



• Apply engine oil to the camshaft bearing 
surfaces. 

» Install the "IN" marked camshaft onto the 

intake side and "EX" marked camshaft onto 

the exhaust side. 
► Turn the camshafts by hand so that the 

timing markes (6) (o; small hole) on the 

camshaft face upward. 
» Install the dowel pins into the cam caps. 

• Install the cam caps (Nos. 3,1 and 4) onto 
the camshaft. 



NOTE: 

• Do not install No. 2 intake and No. 2 ex. 
haust cam caps at this stage. 

• The numbers are punched on the cam- 
shaft caps in increments from right to 
left. 



~> 



3-73 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



4k 



• Tighten the cap bolts. 



NOTE: 

First tighten the No. 3, 1 and 4 cap bolts in 
that order, then the No. 2 cap bolts, 



ffl 



Camshaft Cap: 

10 Nm (1.0 m- kg, 7.2 ft- lb) 




r- 




5. Install: 

• Cam chain sprockets 
By the following installation steps. 



:am chain sprockets installation steps: 

'Align the "T-1" mark (T) on the flywheel 
with the stationary pointer® on the crank' 
case cover use 32 mm wrench. 

CAMTIQ^; 

► Never turn the flywheel installing bolt. 

Rotating the bolt may loosen it, causing the 

rotor to fall out. 
i Do not turn the crankshaft during the 

sprocket installation. 



► Place the cam chain onto the intake 

sprocket. 
» Install the sprocket with the punched mark 

"REAR" facing outward and finger-tighten 

the sprocket bolts. 



MOTE: 

Align the "IN" mark (f) hole on the sprocket 
with the thread hole on the camshaft. 

» Rotate the intake camshaft to align the 
timing mark (4) (o: small hole) on the cam- 
shaft with the embossed match mark @ on 
the camshaft cap (I-4). 



3-74 



ENG 


*im 



ENGINE ASSEMBLY AND ADJUSTMENT 



• Force the intake camshaft counterclockwise 
to remove the cam chain slack. 

• Place the cam chain onto the exhaust 
sprocket. 

• Install the sprocket with the punched mark 
"REAR" facing outward and finger-tighten 
the sprocket bolt. 



NOTE: 

Align the "EX" mark hole on the sprocket 
with the thread hole on the camshaft. 



• Rotate the exhaust camshaft to align the 
timing mark (o: small hole) on the cam- 
shaft with the embossed match mark on 
the camshaft cap (E-4). 

• Force the exhaust camshaft clockwise to 
remove a II the cam chain slack. 

• Insert your finger into the cam chain 
tensioner hole, and push the cam chain 
guide inward. 

• While pushing the cam chain guide, be sure 
camshaft embossed match marks align with 
the timing marks on the camshaft. 

• If marks do not align, change the meshing 
position of sprocket and cam chain. 







6. Install: 

• Cam chain tensioner 
By the following installation steps. 



Cam chain tensioner installation steps: 

• Remove the tensioner end cap bolt and 
spring. 

• Release the cam chain tensioner one-way 
cam (?) , 

• Install the tensioner with a new gasket into 
the cylinder. 



© 



Cam Chain Tensioner Body: 
12 Nm (1.2 m- kg, 8.7 ft- lb) 



.Install the tensioner spring (2) , copper 
washer (f) and end cap bolt® . 



©I 



End Bolt (Cam Chain Tensioner): 
20 Nm (2.0 m- kg, 14 ft- lb) 



3-75 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


%m 



7. Turn the crankshaft and tighten the cam 
sprocket bolts. 



€11 



Camshaft Sprocket: 

24 Nm (2.4 m- kg, 17 ft- lb) 



JAUTJON: 




Be sure to attain the specified torque value to 
avoid the possibility of these bolts coming loose 
and causing damage to the engine. 

8. Install: 

• Cam caps ("I-2" and "E-2") (D ,<D 



ffl 



Camshaft Cap: 

10 Nm (1.0m- kg, 7.2 ft- lb) 



• Cam chain guides (3) , (4) 
9. Apply: 

• Engine oil 

To the cam chain, sprockets, camshaft and 
valves. 





Front Cylinder Head 

When installing the front cylinder head, repeat 
the rear cylinder head installation procedure. 
However, note the following points. 
1. Install: 
• Camshafts 

1) Rotate the crankshaft counterclockwise 
360" plus and added 70" (430° total) 
from the "T-1" mark. 

2) Align the "T-2" (T) mark on the flywheel 
with the stationary pointer (2) on the 
crankcase cover use 32 mm wrench. 

3) Install the cam chain sprockets onto the 
camshafts. 

NOTE: 

Make sure the "FRONT" mark (T) on the cam 
chain sprockets face away from the "IN" mark 
<D and "EX" mark ® on the camshaft. 

4) Turn the camshafts by hand so that the 
timing marks (O: big hole) on the cam- 
shaft face upward. 



3-76 



ENG % m 



ENGINE ASSEMBLY AND ADJUSTMENT 




Install: 

• Cam chain sprocket 

1) Align the "T-2" mark on the flywheel 
with the stationary pointer on the crank- 
case cover use 32 mm wrench. 

2) Install the sprocket with the punched 
mark "FRONT" facing outward and 
finger-tighten the sprocket bolts. 

3) Rotate the intake and exhaust camshafts 
to align the timing mark (O: big hole) on 
the camshaft with the embossed match 
markson the camshaft caps (14 and E-4). 

Measure: 

• Valve clearance 

Out of specification-* Adjust. 
Refer to "CHAPTER 2. VALVE CLEAR- 
ANCE ADJUSTMENT" section. 




Valve Clearance (Cold): 
Intake: 0.11 ~ 0.15 mm 

(0.004- 0.006 in) 
Exhaust: 0.26 " 0.30 mm 
(0.010" 0.012 in) 




OIL DELIVERY PIPE AND CYLINDER HEAD 
COVER 
1. Install: 

• Oil delivery pipe (T) 



NOTE: 

Tighten the three union bolts evenly, then 
torque them to specification. 



ffl 



Oil Delivery Pipe: 
8 mm Bolt: 

18 Nm (1.8m-kg, 13ft-lb) 
10 mm Bolt: 
20 Nm (2.0 m- kg, 14 ft- lb) 



2. Install: 

• Gasket 

• Cylinder head covers (rear and front) 



3-77 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


%m 




NOTE: 

• Be sure all cam caps are covered with oil 
plugs . 

• Arrow mark ® on the cover should face 
toward the exhaust side. 

• Inspect the head cover gasket and replace it 
if damaged. 



3. Tighten: 

• Bolts (cylinder head cover) 
*Spark plugs 



ffl 



Cylinder Head Cover: 

10 Nm (1.0 in* kg, 7.2 ft- lb) 

Spark Plug: 

17.5 Nm (1.75 m- kg, 12.5 ft- lb) 



4. Install: 

• Timing plug (3) 
*Special washer (D 

• Crankcase cover plate ® 

NOTE: 

Check for clog of oil passage (4) in the bolt. If 
any, clean the oil passage. 



V-BOOST 

1. Install: 

• V-boost assembly (T) 



NOTE: 

• Inspect the O-ring (f) on the V-boost, and 
replace it if damaged. 

• Tighten the bolts in a crisscross pattern. 



a 



V-boost: 

10 Nm (1.0 m- kg, 7.2 ft- lb) 



3-78 



ENG 


\^ 



ENGINE ASSEMBLY AND ADJUSTMENT 




REMOUNTING ENGINE 
When remounting the engine, reverse the 
removal procedure. Note the following points. 
1. Install: 

• Down tube frame (right) 

• Bolts (down tube) ©, ©,©,©, ®, <D 

• Bolts (engine)©,© , © 

NOTE: 

Tighten the bolts (#1 ~ #9) in that order. 



ffl 



Engine Mounting: 

Bolts (Down Tube)@, @,®,®: 

45 Nm (4.5 m- kg, 32 ft- lb) 
Bolts (Engine)© : 

70 Nm (7.0nvkg, 50fMb) 
Bolts (Engine)®, ® : 

40 Nm (4.0 m- kg, 29 ft- lb) 
Bolts (Down Tube)® ,® : 

15Nm (1.5 m- kg, 11 ft- lb) 



2. Tighten: 

• Exhaust pipes 

• Muffler 



®Exhaust pipe 

©Muffler 
©Clamp 



I 



10 Nm {1,0m-kg, 7.2 ft- lb) 



25 Nm (2.5 m -kg, ISft-lb) 



7 Nm (0.7 m- kg, 5.1 ft- lb) 




7 Nm (0.7m-kg, 5.1 ft- lb) 



20 Nm (2.0m-kg, 14 ft- lb) 



3-79 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



\m 



3. Tighten: 

• All nuts or bolts 
By the following specification torque. 



© 


Clutch Release Cylinder: 
12Nm(1.2m-kg, 8.7 ft- lb) 




Middle Gear Case Cover: 
10Nm(1.0m-kg, 7.2 ft- lb) 


Change Pedal : 

10 Nm (1.0 m- kg, 7.2 ft- lb) 


Footrest(Left): 
40 Nm (4.0 m- kg, 29 ft- lb) 


Footrest (Right): 
23Nm(2.3m-kg, 17ft-lb) 


Rear Brake Master Cylinder: 
23Nm(2.3m-kg, 17ft-lb) 




4. Adjust: 

o Rear brake switch 
Refer to "CHAPTER 2. REAR BRAKE 
SWITCH ADJUSTMENT" section, 

5. Bend the tabs (T) on the air baffle plate 
(front) as shown. 



6. Adjust: 

• Control cable (V-boost)CD 

Refer to "CHAPTER 5. CARBURETION, 
V-BOOST" section. 

7. Tighten: 

• All nuts or bolts. 

By the following specification torque. 



a 



Conduit: 

7IMm (0.7 m -kg, 5.1 ft- lb) 

Radiator: 

7 Nm(0.7m-kg, 5.1 ft-lb) 

Radiator Cover: 

4Nm (0.4m- kg, 2.9 ft- lb) 

CarburetorJoint: 

10Nm (1.0m-kg, 7.2 ft-lb) 



3-80 



ENG 



\» 



ENGINE ASSEMBLY AND ADJUSTMENT 




8. Connect: 

• All hoses and lead (conduit) 

Refer to "CHAPTER 4. COOLING 
SYSTEM, RADIATOR AND CONDUIT" 
section. 

9. Adjust: 

• Throttle cable free play 

Refer to "CHAPTER 5. CARBURETION, 
THROTTLE CABLE CYLINDER" section. 

10. Add: 

• Engine oil 

Refer to "CHAPTER 2. ENGINE OIL 
REPLACEMENT" section. 

11. Add: 

• Coolant 

Refer to "CHAPTER 4. COOLING 
SYSTEM, COOLANT" section. 






^ 



3-81 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 



\m 



— MEMO — 



3-82 



COOL 



CHAPTER 4. 
COOLING SYSTEM 



sc 



COOLANT 4-1 

COOLANT FLOW 4-1 

COOLANT REPLACEMENT 4-2 

WATER PUMP 4-5 

DISASSEMB LY 4-5 

INSPECTION 4-5 

BEARING AND SEAL REPLACEMENT 4-5 

ASSEMBLY 4-7 

THERMOSTATIC VALVE 4-8 

REMOVAL 4-8 

INSPECTION AND ASSEMBLY 4-8 

COOLANT DRAIN VALVE 4-9 

DISASSEMBLY 4-9 

INSPECTION 4-9 

ASSEMBLY 4-9 

CYLINDER HEAD WATER JACKET JOINT 4-10 

REMOVAL 4-10 

INSPECTION 4-10 

ASSEMBLY 4-10 

RADIATOR AND CONDUIT 4-10 

DISASSEMBLY 4-10 

INSPECTION 4-1 1 

ASSEMBLY 4-12 



cool|% 



COOLANT 



COOLING SYSTEM 



COOLANT 



COOLANT FLOW 
(J) Radiator 

S Coolant drain valve 
Bypass pipe to the coolant drain valve 

(4) Bypass pipe to the thermostatic valve 

(5) Thermostatic valve 

(6) Water pump 

(?) To the reservoir tank 

(8) Thermostat housing 

(9) Conduit 



h- J 




<^D : HOT COOLANT 



COOL COOLANT 



^ 



^ 



^ 



4-1 



COOLANT 



COOL 



X 



COOLANT REPLACEMENT 



ARNING: 



Do not remove the radiator cap when the 
engine and radiator are hot. Scalding hot fluid 
and steam may be blown out under pressure, 
which could cause serious injury. When the 
engine has cooled, open the radiator cap by the 
fo llowing procedure: 

Place a thick rag, like a towel, over the radiator 
cap, slowly rotate the cap counterclockwise 
to the detent. This procedure allows any residual 
pressure to escape. When the hissing sound has 
stopped, press down on the cap while turning 
counterclockwise and remove it. 

1. Place a receptacle under the coolant drain 
bolt. 




2. Remove: 
"Cover (right) 
•To cover 
• Radiator cap (T) 
*Feed hose (reservoirtank) (2) 



3. Align: 

• Coolant drain valve "ON" (T) mark with 
match mark (2) on drain valve housing 



Remove: 
*Drain bolt 
Drain the coolant. 



4-2 



COOL }? 



COOLANT 







m , - ., 


1. 




5 . R em ove : 

• Sldel coveis (cylinder) (T) 






6 . R em ove : 

• Rubberlpiigs (p 

D rail the coolant. 

NOTE: 

To facilitate removal of the rubber plug's, 
screw a spark plig iito the threaded hot and 
hand-pul the spark plig firm ly. 



7. Drah: 

*C oo !ant (com p le te ly ) 



NOTE : 

Thoroughly fhsh the coolhg system w ith cfean 
tap water, 

8 . Inspect: 

*Rubber pligs 
D am age "* R epiace , 
9. Tghten: 

• Drairi bolt 



£& 



Drain Bolt: 

43 Nm (4 3 m kg, 31 ft.lb) 



10. FiH: 

• C oolhg system 
By the fblbwing steps. 



«a 



Recommended Coolant: 

H igh Q uality Ethylene G lycol 
Anti-Freeze Containing Anti- 
Corrosion forAlim inum Engine 
Inhibitors 

Coolant and W ater M ixed Ratio : 
50% /50% 

Total Am ount: 

3.05 L (2.69 Imp qt, 3.22 US qt) 



COOLANT COOL 



X 



Reservoir Tank Capacity: 

0.30L (0.26lmpqt, 0.32USqt) 

From "LOW" to "FULL" Level: 
0.20 L (0.18 Imp qt, 0.21 US qtj 



CAUTION: 



"Hard water or salt water is harmful to the 

engine. You may use distilled water if you 

can't get soft water. 
• Do not mix more than one type of ethlen 

glycol antifreeze containing corrosion for 

aluminum engine inhabitors. 



CD 



0= 




Coolant filling steps: 

• Fill the coolant into the conduit until the 

conduit isfull. 
*Start the engine (coolant level decreases.) 

CAUTION: 



Always check coolant level, and check for 
coolant leakage before starting engine. 



•Add the coolant while engine is running. 
*Stop the engine when coolant level stabilizes. 
•Add the coolant again to specified level . 
*lnstall the radiator cap. 
*Align the coolant drain valve "OFF" mark 

(2) with the match mark (§) on drain valve 

housing. 



11. Connect: 

*Feed hose (reservoirtank) 

12. Fill: 
*Reservoir tank 

Add the coolant until liquid reaches 
"FULL" level mark. 

® "FULL" level 
(2) "LOW" level 



4-4 



|cqql| % 



WATER PUMP 




WATER PUMP 
DISASSEMBLY 
NOTE: 





• Be sure to drain the coolant before disassembly 

of the cooling system components. 
*Refer to Engine Disassembly for water pump 

disassembly . 

1. Remove: 

• Circlip (D 
*Drive gear (2) 
*Gear stopper pin (§) 

• Circlip (4) 
Impeller shaft @ 

2. Eliminate: 

• Deposits 

From the impeller and water pumphousing. 



INSPECTION 

1. Inspect: 
*Bearing 

Wear/Damage^ Replace. 
•Oil seal 

Wear/Damage -> Replace. 

• Impeller 
Cracks/Wear/Damage -* Replace. 

*Water pump seal set (T) 
Wear/Damage-^ Replace. 

BEARING AND SEAL REPLACEMENT 

1. Remove: 
*Bearing 
•Oil seal (5) 

Tap off both components from water pump 
seal side. 

(3) Crankcase cover 

2. Remove: 

• Water pump seal (crankcase side) (Tj 
Tap it off from the cover (f). 



^ 



^ 



4-5 



WATER PUMP 



COOL 



X 




3. Install: 

•Water pump seal (D 
Use Water Pump Seal Installer (YM-04058- 

1 <D,YM-33221(D). 

Apply Sealant (Quick Gasket®) to crank- 
case cover @ before installing seal. 



El PRESS 

□ APPLY SEALANT (QUICK GASKET®) 

4. Remove: 
• Seal No. 2 (T) 
From impeller. 
Pry out with a small screwdriver. 





\ t^' f 






VQ< 


c 


// / 


=# 


EH=jv 


^1 


V® 




NOTE: 

Be careful not to scratch or bend the impeller 
shaft. 

(2) Damper rubber 

5. Apply: 

•Water or coolant 
To outer surface of damper rubber (f) and 
impeller hub. 

CAUTION: 

Never apply oil or grease to water pump seal 
surfaces. 

6. Assemble: 

•Seal No. 2/Damper rubber (f) 
To impeller hub. 

CD S|j p rin g 

(3) Impeller 

E APPLICATION OF WATER OR COOLANT 

7. Measure: 
*Tilt 

Out of specification -*■ Repeat the above 
steps "4 ~ 6". 

NOTE: 

Be sure seal No. 2 fits squarely. 




Tilt Limit: 0.15 mm (0.006 in) 



(T) Straight edge 
(2) Seal NO. 2 
(3j Impeller 



4-6 



COOL 



K 



WATER PUMP 




ASSEMBLY 







(j) Impeller 

(5) Mechanical seal 

(3) Oil seat 

(4) Bearing 
© Circlip 

(6) Gear stopper pin 

(7) Drivengear 

(8) Drive gear 

(9) Water pump cover 
@ O-ring 

(jj) Crankcase cover 

E FRONT 

[b from radiator 
□ to cylinder 

1. Install: 

• Impeller shaft (f) 
•Circlip © 

• Gear stopper pin (§) 

• Drive gear (2) 

• Circlip (T) 

CAUTION: 



• Be sure not to scratch the water pumpmechani 
cal seal while installing. 

• Replace any scratched seal. 



4-7 



THERMOSTATIC VALVE 



COOL 



X 



12 Nm 11 .2m -kg. 8.7 ft-lb) 




12 Nm 11.2 m-kg 8.7fflb) 



95 C<203 F] 

80 - 84 S C 
(176~183°F) 







i J> i 6 * 




8 mm (0.31 in) 



82° ± 2°C 95°C 

<180°±3.6°FI (303 ° Fl 



THERMOSTATIC VALVE 

REMOVAL 
1. Remove: 

• Thermostat cover © 

• Thermostatic valve (2) 



(3) Thermostat housing 

INSPECTION AND ASSEMBLY 

1. Inspect: 
Thermostatic valve 
Valve does not open at 80 ~ 84°C (176' 
183°F)^- Replace. 
By the following inspection steps. 



Thermostatic valve inspection steps: 

•Suspend thermostatic valve in a vessel or 
water. 

• Place reliable thermometer in water. 

• Heat water slowly. 

• Observe thermometer, while stirring water 
continually 



(T) Thermometer (4) Water 

(I) Full open (§) Thermostatic valve 

(3) Opening sequence begins (f) Vessel 

E OPEN [H CLOSE 

NOTE: 

Thermostat is sealed and its setting is specialized 
work. If its accuracy is in doubt, always replace 
it. A faulty unit could cause serious overheating 
orovercooling. 



4-8 



COOL 



X 



COOLANT DRAIN VALVE 




2. Inspect: 

• O-ring (T) 
Wear/Damage-* Replace. 



3. Install: 

.Thermostatic valve (T) 

NOTE: 



Line up the valve breather hole (2) with the 
housing projection (f) . 

•Thermostat cover 
• Thermostat housing 



COOLANT DRAIN VALVE 

DISASSEMBLY 

1. Remove: 
.Retaining screw (T) 
• Valve assembly 



INSPECTION 

1. Inspect: 
• 0-ring(i) 

Wear/Damage ->• Replace. 
•Spring (2) 

Damage ->• Replace. 
.Stopper ball (f) 

Wear/Damage^- Replace. 



ASSEMBLY 

1. Install: 

• Valve assembly 
Be sure stopper ball falls into body cavity. 

2. Secure valve assembly with retaining screw. 



4-9 



CYLINDER HEADWATER JACKET JOINT/ 
RADIATOR AND CONDUIT 



coolTJS 



r^ 




CYLINDER HEADWATER JACKET 
JOINT 

CAUTION: 



• Be sure to drain the coolant before you disas- 
semble the water jacket joints otherwise the 
coolant will flow into the crankcase. 

• Do not remove the water jacket joints unless 
absolutely essential; e.g., when overhauling 
the engine. 



REMOVAL 

1. Remove: 
.Stopper pins (T) 
•Water jacket joints (2) 



INSPECTION 
1. Inspect: 
•Water jacket joint (T) 
Clogging-*- Clean. 

• O-rings (2) 
Wear/Damage^- Replace. 

• Stopper pin(f) 
Wear/Bends^ Replace. 



ASSEMBLY 

1. Install: 
•Water jacket joints ® 
•Stopper pins (2) 



RADIATOR AND CONDUIT 

DISASSEMBLY 

1. Drain: 
• Coolant (completely) 
Refer to "COOLANT REPLACEMENT" 
section. 



4-10 



COOL 



X 



RADIATOR AND CONDUIT 




2. Remove: 

• Bolts (radiator) 

3. Disconnect: 

• Upper hose (T) 

• Lower hoses (2) 



4. Disconnect: 

• Fan motor coupler 

5. Remove: 

• Radiator assembly 



6. Disconnect: 

• All hoses and leads (conduit) 

7. Remove: 
•Screws (conduit) 



8. Remove: 
• Fan motor assembly 



INSPECTION 
1. Inspect: 

• Radiator 

Obstruction -> Blow out with compressed 

air through rear of radiator. 
Flattened fins ->■ Repair. 

• Coolant hoses 
Cracks/Damage -> Replace. 



4-11 



RADIATOR AND CONDUIT 



coolTJJS 




2. Inspect: 

*Vacuum valve spring 

Fatigue-^ Replace. 
*Vacuum valve seating condition 

Poor condition -+ Replace. 

3. Measure: 

*Valve opening pressure 
By the following measurement steps. 



Valve opening pressure measurement steps: 
• Measure the radiator cap pressure using the 

Radiator Cap Tester ® (YU-24460). 

Valve opens at pressure below specified valve 

or defective -+ Replace. 



Valve Opening Pressure: 

73.6" 103.0kPa (0.75 " 1.05 kg/cm 2 
10.7- 14.9lb/in 2 ) 



ASSEMBLY 

When installing the radiator and conduit, 
reverse the removal procedure. Note the 
following points. 
1. Install: 
• Conduit 



fij 



Screws (Conduit): 

7Nm(0.7m-kg, 5.1 ft. lb) 



2. Connect: 

• All hoses and leads (conduit) 

NOTE: 



Align the hose match marks (T) with the 
match marks (2) on the conduit. 



3. Install: 
• Radiator assembly 



£J 



Bolts (Radiator): 
7Nm (0.7m.kg, 5.1 ft-lb) 



4. Fill: 

*Cooling system 
Refer to "COOLANT REPLACEMENT" 
section. 

4-12 




RADIATOR AND CONDUIT 




5. Inspect 

*Cooling system 
By the following inspection steps. 



Cooling system inspection steps: 

• Connect Radiator Cap Tester (YU-24460) 

CD- 

*Apply 1.0kg/cm 2 (1 4 lb/in 2 ) pressure. 
*Measure pressure with gauge. 

Decrease of pressure (leaks) -> Repair at 
required. 



4-13 



CHAPTER 5. 
CARBURETION 



CARB M 



CARBURETOR .... 

SECTION VIEW . 
REMOVAL 
DISASSEMBLY . 
INSPECTION . . . 
ASSEMBLY .... 
INSTALLATION 
ADJUSTMENT . 



5-1 
5-2 
5-3 
5-3 
5-6 
5-7 
5-8 
5-9 



THROTTLE CABLE CYLINDER 
ADJUSTMENT 



5-10 
5-10 



V-BOOST 

REMOVAL .... 
INSPECTION . . . 
ADJUSTMENT . 
INSTALLATION 



5-13 
5-13 
5-13 
5-13 
5-15 



AIR CLEANER AND CRANKCASE VENTILATION SYSTEM 5-16 



a 



CARB £ 



CARBURETOR 



CARBURETOR 



CARBURETION 



^ 



(f) Throttle cable (Close side) © 

(£) Throttle cable (Open side) © 

(D Fuel overflow hose © 

® Fuel feed hose 

(f) Syncronization rod ® 

(6) Float needle valve © 

(7) Needle j e t screw 

(D Float @ 

(9) Mainjet 

@ Main bleed pipe (g) 

(Q) Rubber plug @ 

@ Fuel drain hose (g) 

(0) Pilotjet (5|) 



Jet block 
Starter lever shaft 
Fuel overflow hose 
Fuel feed hose 
Pilot air jet No. 1 
Coasting enrichment 
valve assembly 

Pilot air jet No. 2 
Piston valve assembly 
Tamper proof screw 
Starter plunger assembly 
Starter body 
Piston valve center mark 





Mainjet 


#1 &#3: #152.5 




#2&#4 :# 150 


Main air jet 


2.0 


Jeet needle 


5EZ43 


Needle jet 


Y-0 


Pilotjet 


#37.5 


Fuel level 


16+ 1.0 mm 




(0.63± 0.04 in) 


Pilot screw 


Preset 


Valve seat size 


1.5 


Engine idle speed 


1,000 t 50r/min 



-^ 




-~> 



^ 



~> 






5-1 



CARBURETOR 



CARB 



* 



SECTION VIEW 






(J) Air vent 


1? 


Pilot screw 


(5) Pilot air jet No. 1 


v; 


Bypass hole 


(3) Main air jet 


© 


Pilot outlet 


(4) Jet needle 


® 


Purge hole 


(f) Pilot air jet No. 2 


<&> 


Throttle valve 


(6) Piston valve 


ifc 


Pilot jet 


(7) Diaphragm 


© 


Main jet 


(|) Purge jet No. 2 


© 


Main bleed pipe 


(9) Purgejet No. 1 


;? 


Needle jet 



<^> 




A 


<=^ 


AIR 


B 


<&H3 


MIXTURE 


C 


^ 


FUEL 



5-2 



CARB 



* 



CARBURETOR 



REMOVAL 
1. Remove: 
• Carburetor assembly 
Refer to engine removal section. 

NOTE: 



The following parts can be cleaned and inspected 
without disassembly. 

• Piston valve 

• Starter plunger 

• Coasting enrichment valve 




DISASSEMBLY 
CAUTiON: 



The plastic piston valve is fragile and highly 
susceptible to damage. Be sure to handle with 
extreme care. Do not drop the valve or subject 
it to undue abuse as this can cause cracks that 
could severely weaken the piston valve. 

1. Remove: 

• Fuel lines 

2. Number each carburetor before removing it 
from carburetor bracket. 

3. Remove: 

• Upper brackets 



ffl FRONT 

4. Remove: 

• Lower brackets 



5-3 



CARBURETOR 



CARB 



* 




5. Remove: 
•Side brackets (f) 



6. Remove: 

•Starter lever shafts 



7. Remove: 
*Synchronization screws (£) 
*Synchronization rod (2) 

NOTE: 



When separating the carburetors be sure not to 
lose the small spring that may fall out. This 
spring connects the throttle levers. 



8. Remove: 

•Starter plunger (T) 
•Starter plunger body (5) 



(D Nut 
(4) Spring 

9. Remove: 

*Vacuum chamber cover ® 
Use the Special Torx Driver {YU-25359-2). 



(2) Tamperproof screw 



5-4 



CARB ff 



CARBURETOR 




10 . Rem ove: 

• Sprhg (£j 

• Vacuum piston (2) 

• O -rhg (3) 

• Pibtair J2tNo.2 (4) 



11. Remove: 

• C oasthg enrchm ent cover(T) 

•Spring (2) 

• D aphragm (3) 




12 . R em ove : 

• Fbat cham ber cover 

•Floa* © 

• N eedfe valre (2) 



13 . R em ove : 

• Mail ^t(Jj 
•Jetl block (2) 



" 



14 . R em ove : 

• Gasket(J| 

•0-rind © 

• Needfe J5t(3) 

NOTE : 

Move the needie pt tow aid the vacuum piston. 



"> 



5-5 



^ 



"~ 



CARBURETOR 



CARB 



* 




15. Remove: 

• Rubber caps (T) 

• Pilot jet (D 

• Main bleed pipe (§) 



16. Remove: 

• Pilot air jet No. 1 (D 



INSPECTION 

1. Inspect: 
• Carburetor body 
Contamination-* Clean. 

NOTE: 

Use a petroleum based solvent for cleaning. 
Blow out all passages and jets with compressed 

air. 






2. Inspect: 

• Float 

Damage -► Replace. 

• Needle valve 
Wear/Contamination ■ 



Replace. 




3. Inspect: 

• Vacuum piston (£ 
Cracks -*■ Replace. 

NOTE: 



If you suspect the piston valve has been dam- 
aged, check the component for cracks by 
pouring gasoline into the valve. If it leaks, 
replace with a new piston valve. 



5-6 



CARB 



* 



CARBURETOR 




4. Inspect: 
•Jet needle 
Bends/Wear - 



Replace. 



5. Inspect: 
• Diaphragm (£ 
Tears -» Replace. 



6. Inspect: 

• Starter plunger 
Damage/Wear -» Replace. 

7. Inspect 

• O-ring 
•Gasket 

Damage -> Replace. 



ASSEMBLY 

To assemble the carburetors, reverse the disas- 
sembly procedures. Note the following points. 



CAUTION: 



• Before reassembling, wash all parts in clean 

gasoline. 
•Always use a new gasket. 




1. Install: 

• Needlejet (f) 

• O-ring (2) 
•Gasket 

NOTE: 

Make sure the projections on the carburetor 
body are meshed with the holes on the gasket. 



5-7 




CARBURETOR 


CARB 


* 


2. Install: 
• Jet block 

NOTF- 


Make sure the projection © on the jet block is 
meshed with the groove (D on the needle jet. 



3. Install: 

• Coasting enricher © 

• Vacuum piston (2) 
•O-ring (f) 

NOTE: 



There is a tab on the rubber diaphragm and a 
matching recess in the carburetor body to 
accept the diaphragm tab. 

4. Install: 

•Starter lever shafts © 
Apply LOCTITE® to the starter plunger 
lever securing screws. 



5. Install: 

• Mounting brackets: 
Apply LOCTITE® to the bracket securing 
screws. 

NOTE: 

When reassembling, the surface plate © should 
be used for proper carburetor alignment. 



m 



Screws (Mounting Brackets): 
5Nm(0.5m-kg,3.6fMb) 



INSTALLATION 

1. Install: 
• Carburetors 
Reverse the removal steps 



5-8 



CARB 



* 



CARBURETOR 




ADJUSTMENT 

1. Measure: 
• Fuel level 
Out of specification -* Adjust. 
By the following measurement steps. 




Fuel Level: 

16+ 1.0 mm (0.63 ± 0.04 in) Below 
the Carburetor Piston Valve Center 



Fuel level measurement steps: 

• Place the motorcycle on a level surface. 

• Use a garage jack under the engine to ensure 
that the carburetor is positioned vertically. 

• Connect the Fuel Level Gauge ® 
(YM-01312) to the drain pipe (2) using a 
level gauge adapter (f) . 

• Loosen the drain screw (?) and warm upthe 
engine for several minutes. 

• Measure the fuel level (a) with the gauge. 
(D Piston valve center mark 

• Repeat the above procedure for other 
carburetors. 

• If the fuel level(s) is incorrect, adjust the 
fuel level(s). 



^ 




2. Adjust: 
• Fuel level 
By the following adjustment steps. 



Fuel level adjustment steps: 

• Removethe carburetors. 

• Inspect the needle valve. 

• If it is worn, replace it. 

• If it is fine, adjust float level by bending the 
float tang (Jj slightly. 

• Repeat the procedure for the other carbure- 
tors. 



""> 



"> 



5-9 



THROTTLE CABLE CYLINDER 



THROTTLE CABLE CYLINDER 



(T) Cable cylinder 

(j) Slider 

(D Cable adjustment 

mark (Open side) 
(?) Standard adjuster 

distance 

(5) Cable adjuster 
(Carburetor side) 

(6) Locknut (Carburetor side) 



(7) Throttle stop screw 

(§) Silver tape 

(9) Cable adjustment 

mark (Close side) 
I'll) Cable adjuster 

(Throttle grip side) 
(fj) Turning direction 
(f|) Free play 

(Throttle grip) 





ADJUSTMENT 
1. Loosen: 
.Throttle stop screw (j) 
To set the throttle valve to full closed. 



2. Adjust: 
• Distance (a) 
Between the threaded end of the tubular 
control cable guide and the adjuster. 




Standard Carburetor Side Adjuster 
Distance: 

15 mm (0.59 in) 



5-10 



CARB 



* 



THROTTLE CABLE CYLINDER 




3. Measure: 
• Free play (throttel grip) (a) 
Out of specification -> Adjust. 




Throttle Grip Free Play : 
4 ~ 7 mm (0.16~ 0.28 in) 



4. Check: 

• No. 2 carburetorthrottle valve operation 
By the following checking steps. 






No. 2 carburetor throttle valve operation 
checking steps: 

• Loosen the locknut (carburetorside) (7) . 
•Turn throttle grip back and forth. 

• Check No. 2 carburetorto see if the throttle 
valve operates at full open and full closed. 
Operation of throttle valve normal -> Tighten 
locknut© . 

Throttle valve fails to operate at full closed 
-> Adjust. 

E THROTTLE VALVE FULLY OPEN 
iB THROTTLE VALVE FULLY CLOSED 



~> 



5. Adjust: 

• No. 2 carburetor throttle valve operation 
By the following adjustment steps. 



No. 2 carburetor throttle valve operation 
adjustment steps: 
First step: 

a. Loosen the locknut (carburetorside). 

b. Turn the adjuster (carburetorside) clock- 
wise a little. 

c. Turn the adjuster (throttle grip side) coun- 
terclockwise and adjust free play (throttle 
grip)towithin 4 ~ 7 mm (0.16~ 0.28 in). 

d. Check to see if throttle valve operates at 
full closed. 

I f not, repeat steps a ~ d. 

e. Set the throttle valve at full closed and 
tighten locknut (carburetorside). 

f. Check to see if throttle valve operates at 
full open. 

Throttle valve fails to operate at full open 
-> Perform the next step. 



""> 



"^ 



5-11 



THROTTLE CABLE CYLINDER 



CARB 



« 



- . 


%* 


1 1 

1 1 

J— L 


oi ; 


f : 



o 

&n 

DC 

'O 

Ul 

DC 

D 

CO 

DC 
< 


i 

z 

S 

o 

1 




1 

llT "I 

i 

ft 


\ 


Fi® 



Second step: 

a. Loosen the locknut (carburetor side). 

b. Turn the adjuster (carburetor side) counter- 
clockwise a little. 

c. Turn adjuster (throttle grip side) clock- 
wise so that the free play (throttle grip) is 
within 4 " 7 mm (0.16" 0.28 in). 

d. Check to see if throttle valve operates at 
full open. 

If not, repeat steps a ~ d. 

e. Tighten locknut (carburetor side). 

f. Check to see if throttle valve operates at 
full open or full closed. 

Throttle valve fails to operate at full open 
or full closed^ Perform the next step. 

Third step: 

• Check to see if throttle cable installation 
i s correct. 



NOTE: 

Be sure that the silver throttle cable (3) is po- 
sitioned opposite the adjusters. 



Check the position of the control cable 
sliders in the throttle cable cylinder. 



NOTE: 

• Be sure the open side slider (silver cable side) 
falls between the three adjustment marks on 
the carburetor side. 

• Be sure the closed side slider falls between 
the two adjustment marks on the throttle 
grip side. 



»lf the slider(s) fall outside the adjustment 
marks then the throttle cable(s) must be 
replaced. 



(T) Cable adjustment mark (Open side) 
(5) Cable adjustment mark (Closed side) 



5-12 



CARB 4 



V-BOOST 



6. Install: 

• Air cleaner 

7. Set engine idle speed. 



A 



Idle Speed: 1.000 r/m in 



VBOOST 

REMOVAL 

1. Remove: 
• V-boost assembly 
Refer to engine removal section. 

NOTE: 



The V-boost can be inspected without the 
disassembly. It is not necessary to disassemble 
the V-boost. 




INSPECTION 

1. Inspect: 

• V-boost body 
Contamination -* Clean. 

Use a petroleum based solvent. 

• Butterfly valves (T) 

Damage/Wear-* Replace V-boost assembly. 



ADJUSTMENT 
NOTE: 



These adjustments are only required when 
following part(s) is replaced. 
•Servo motor 

• Cantrol cable 

• Control cablejoint 
Carburetorjoint 



Control Cable Adjustment 

ITurn on the main switch for the servo 
motor initial operation (valve closed po- 
sition). 



5-13 



V-BOOST 



CARB 



* 




2. Measure: 
• Clearance (a) 
Between the pulley (T) and the adjuster (2) 
Out of specification ■+ Adjust. 



•(ojh Clearance (a) : 

\^\| 0.3 ±0.1 mm (0.012 ±0. 



004 in) 



(D Lockunt 

3. Adjust: 
•Clearance 
By the following adjustment steps. 




Clearance adjustment steps: 

First step: 

NOTE: 



Do not loosen the locknut© in this stage. 



• Loosen the lock bolt (2) . 
•Turn on the main switch for the servo motor 
initial operation (valve closed position). 
NOTE: 



By performing these steps, and appropriate 
tension for the control cable 1 (T) can be 
obtain with the spring (4) in the joint (3) . 



•Tighten the lock bolt to specification. 




Lock Bolt: 
3.5 Nm (0.35 m.kg, 2.5 ft-lb) 



• Measure the clearance (a) . If not, perform 
the next step. 

Second step: 

• Loosen the locknut ©. 

•Turn the adjuster (6) clockwise or counter- 
clockwise until proper clearance is attained. 

•Tighten the locknut. Apply LOCTITE® to 
the locknut. 

(7) Pulley 



5-14 



CARB 



# 



V-BOOST 




V-boost Synchronization 
NOTE: 



Before synchronizing the V-boost, the control 
cable should be adjusted. 



a- 



m 



Clearance a 

0.4 ± 0.1 mm (0.01 6 ± 0.004 in) 



2. Adjust: 
• Clearance 
By the following adjustment steps. 



V-boost synchronization adjustment step: 

• Loosen the locknut® . 

•Turn the adjuster (2) clockwise or counter- 
clockwise until proper clearance is attained. 

• Measure the clearance. If not, repeat above 
step. 

•Tighten the locknut. Apply LOCTITE® to 
the locknut. 



INSTALLATION 

1. Install: 
•V-boost assembly 
Reverse the removal steps. 



^ 



5-15 



AIR CLEANER AND CRANKCASE VENTILATION SYSTEM 



CARB 



* 



AIR CLEANER AND CRANKCASE VENTILATION SYSTEM 

Refer to "CHAPTER 2" for the air cleaner maintenance. 



(J) Air cleaner 
(2) Carburetor 
(D V -boost 




5-16 



CHAS 



<3^% 



CHAPTER 6. 
CHASSIS 



FRONT WHEEL 6-1 

REMOVAL 6-2 

INSPECTION 6-2 

INSTALLATION 6-4 

REAR WHEEL 6-6 

REMOVAL 6-7 

INSPECTION 6-7 

INSTALLATION 6-8 

FRONT AND REAR BRAKE 6-9 

CALIPER PAD REPLACEMENT 6-11 

CALIPER DISASSEMBLY 6-12 

MASTER CYLINDER DISASSEMBLY 6-13 

BRAKE INSPECTION AND REPAIR 6-16 

BRAKE REASSEMBLY 6-17 

AIR BLEEDING 6-19 

BRAKE DISC INSTALLATION 6-20 

HYDRAULIC CLUTCH 6-21 

CLUTCH RELEASE DISASSEMBLY 6-22 

MASTER CYLINDER DISASSEMBLY 6-22 

CLUTCH INSPECTION AND REPAI R 6-23 

CLUTCH REASSEMBLY 6-24 

AIR BLEEDING 6-25 

FRONT FORK 6-27 

REMOVAL 6-28 

DISASSEMBLY 6-29 

INSPECTION 6-30 

ASSEMBLY 6-31 

INSTALLATION 6-33 

STEERING HEAD 6-35 

REMOVAL 6-36 

INSPECTION 6-38 

INSTALLATION 6-38 

REAR SHOCK ABSORBER 6-40 

REMOVAL 6-41 

INSPECTION 6-41 

INSTALLATION 6-41 



u 



CHAS 



<2^% 



SWINGARM 6-43 

FREE PLAY INSPECTION 6-44 

REMOVAL 6-44 

INSPECTION 6-45 

INSTALLATION 6-46 

SHAFT DRIVE 6-47 

TROUBLESHOOTING 6-48 

FINAL DRIVE GEAR 6-52 

DRIVE SHAFT 6-62 



"> 



CHAS 



ofcfe 



FRONTWHEEL 



CHASSIS 



FRONTWHEEL 

Collar 

(2) Oil seal 

(3) Bearing 

(4) Spacer 

(5) Spacer flange 



©Bearing 
©Meter clutch 
@Clutch retainer 
CS) Oil seal 
(OS) Gear unit assembly 



MINIMUM DISC THICKNESS: 
7.0 mm {0.28 in) 



MAXIMUM DIFLECTION: 
0.15 mm (0.006 in) 



/@ 




TIRESIZE: 
110/90 V-1 8 



WEAR LIMIT; 
1.0 mm {0,04 in) 



E 


RIM SIZE: 


MT2.50x 18 




RIM RUNOUT LIMIT: 




RADIAL: 


F 


2.0 mm (0.08 in) 




LATERAL: 




2.0 mm (0.08 in) 



^ 



6fl-Nm (6.0m-kg,43fflb) 



6-1 



FRONT WHEEL 



CHAS 



ofafc 




REMOVAL 



WARNING; 



Securely support the motorcycle so itwon't fall 
over when the front wheel. 

1 . Place the motorcycle on its centerstand. 

2. Remove: 
@Speedometecable (T) 

3. Remove: 

• Fork brace © 

• Front fender (2) 



4. Loosen: 

• Pinch bolt (frontaxle) (D 

• Frontaxle (2) 

5. Elevate the front wheel by placing a suitable 
stand under the engine. 

6. Remove: 

• Frontaxle 

• Front wheel 

Lower the wheel until the brake discs come 
off the calipers. Turn the brake calipers out- 
ward so they do not obstruct the wheel. 

NOTE: 

Do not squeeze the brake lever while the wheel is 
off the motorcycle. 



_ ®t 




It 


\ 


G? 


\N fJj® 




in 


> 



INSPECTION 

1. Inspect: 

• Tire 
Tire tread shows crosswise lines (minimum 
tread depth)/Cracks -> Repalce. 




Minimum Tire Tread Depth: 
1.0 mm (0.04 in) 



(T) Tread depth (2) Side wall (D Wear indicator 



6-2 



CHASofc 


FRONTWHEEL 










^A 


2. Inspect: 
• Frontaxle 
Bends -> Replace. 
Roll the axle on a flat surface 


fTTTTTlT 


^tJ 








1 WARMING:! 


Do notattempt to straighten a dent axle. 








™S" 



3. Inspect: 

• Wheel 
Cracks/Bends/Warpage^ Replace. 

4. Measure: 

• Wheel runout 

Over specified I i m it -> Repalce. 




Rim Runout Limits: 

Radial (T): 2.0 mm (0.08 in] 
Lateral (£): 2.0 mm (0.08 in; 




5. Check: 

• Wheel balance 
Out of balance -> Adjust. 

NOTE; 



Balance wheels with the brake discs installed. 



CAUTION: 



Be sure the valve stem locknut is tightened 
securely after repairing or replacing a tire and/or 
wheel. 



WARMING. 



Ride conservatively after installing a tire to allow 
the tire to seat itself correctly on the rim. 

6. Inspect: 

• Wheel bearings 
Bearings allow play in the wheel hub or 
wheel turns roughly^ Repalce. 
By the following replacement steps. 



Wheel bearing replacement steps: 

• Clean the outside of the wheel hub. 

• Drive out the bearing. 



6-3 



r- 



FRONT WHEEL 




CHAS 



<§&<$> 



WARNING: 



Eye protection is recommended when using 
striking tools. 



• Install the new bearing by reversing the 
previous steps. 



NOTE: 

Use a socket that matches the outside diameter 
of the race of the bearing. 



cAmtottt 



Do not strike the center race or balls of the 
bearing. Contact should be made only with the 
outer race. 



7. Inspect: 
• Brake disc 
Wear/Over specified limit - 



Replace. 




Maximum Deflection 
(Front and Rear): 
0.15 mm (0.006 in) 

Minimum Disc Thickness 
(Front and Rear): 
7.0 mm (0.28 in) 




INSTALLATION 

When installing the front wheel, reverse the 

removal procedure. Note the following points. 

1. Apply: 

• Lithium base grease 

Lightly grease to the oil seal and gear unit. 

2. Install: 

• Gear unit assembly 

NOTE: 

Be sure that the two projections inside the 
wheel hub mesh with the two slots in the gear 
unit assembly. 



6-4 



FRONTWHEEL 




3. Install: 

• Front wheel 
NOTE: 



• Be sure that the projecting portion (torque 
stopper) (D of the gear unit housing is position- 
ed correctly. 

.Compress the front forks several times to con- 
firm proper fork operation before tightening 
the pinch bolt. 



4. Tighten: 
• Front axle 



ffl 



Front Axle 

60 Nm (6.0nvkg,43ft-lb) 



5. Tighten: 

• Pinch bolt (front axle) 

• Fork brace 

• Front fender 



ffl 



Pinch Bolt (Front Axle): 
20 Nm (2.0m-kg, 14ft lb) 

Nuts (Fork Brace): 

9 Nm (0.9 m kg, 6.5 ft- lb) 



""> i 



^ 



6-5 



REAR WHEEL 



CHAS 



ofcfc 



REAR WHEEL 

® Oil seat 
©Circlip 
(D Bearing 
©Spacer flange 

@ Spacer 
©Collar 



(f) Cylinder bearing 

(D Oil seal 

(9) Clutch hub 

(Q) Damper 

(Q) Hub dust seal 

© Circlip 



■ ^ 



^ 



tf 



MINIMUM DISC 
THICKNESS: 
7.0 mm (0.28 in) 



B6304RS 



G USE A NEWONE 




MAXIMUM DEFLECTION: 
0,15 mm (0.006 in) 



A 


TIRE SIZE: 


150/90 V1 5 


B 


WEAR LIMIT; 


1.0 mm (0.04 in) 


C 


RIM SIZE: 


M73.50x 15 




RIM RUNOUT LIMIT: 




RADIAL: 


D 


2.0 mm (0.08 in! 




LATERAL: 




2.0 mm (0.08 in) 



120Nm(12.0nvkg,85fflb) 



6-6 



CHAS 



ofcfc 



REAR WHEEL 



v \v v. 


1 J^j 




i\\^ 




REMOVAL 

1. Place the motorcycle on its centerstand. 

2. Remove: 
*Cotter pin ® 
*Axle nut (§) 
• Washer 



3. Remove: 

• Rear caliper 

• Tension bar 
NOTE: 



Do not depress the brake pedal when the wheel is 
off the motorcycle as the brake pads will be 
forced. 

4. Loosen: 

• Pinch bolt (rear axle) (f) 

5. Remove: 

• Rear axle 

While supporting the brake caliper, pull 
out the rear axle. 

• Rear wheel 

Move the wheel to the right side to separate 
it from the final gear case. 



INSPECTION 

1 . Inspect: 
*Tire 

• Rear axle 

•Wheel 

• Wheel bearings 

• Brake disc 

Refer to "FRONT WHEEL - INSPEC- 
TION" section. 

2. Measure: 

• Wheel runout 

Refer to "FRONT WHEEL - INSPEC- 
TION" section. 

3. Check: 

• Wheel balance 

Refer to "FRONT WHEEL - INSPEC- 
TION" section. 



6-7 



REAR WHEEL 



CHAS|<^3fe| 




INSTALLATION 

When installing the rear wheel, reverse the re- 
moval procedure. Note the following points. 

1. Apply: 

• Lithium base grease 

Lightly grease to the final gear case splines. 

2. Install: 

• Rear wheel assembly 

NOTE: 

Be sure the splines on the wheel hub fit into final 
gear case. 

3. Tighten: 

• Wheel axle 



£3 



Axle Nut: 

120 Nm (12.0m -kg, 8 5 ft- lb) 

Pinch Bolt (Rear Wheel): 
20Nm (2.0m.kg, 14ft.lb) 









V ( .V 


f/fA L\\ 






' 1 1 

i » 

i ■ 


i \W 


1_ . -Sf \ \ 






H 1 


J \\ 




L_r^ YJ=L 





CAUTION: 



Always use a newcotter pin on the rear axle nut. 

4. Tighten: 
*Tension bar 
• Rear caliper 



a 



Rear Caliper: 

45 Nm (4.5m-kg, 32ft-lb) 



r* 



6-8 



CHAS 



<£%•> 



FRONT AND REAR BRAKE 



FRONT AND REAR BRAKE 

® Air bleed screw E-(a) : Install the pad spring with its longer tangs (a) in the 

(2) Retaining pin disc rotating direction. 

(3) Dust seal 

(4) Piston seal 
© Piston 
(D Circlip 



A FRONTCALIPER 



[5 Nm (0.5nvkg, 3.6 ft -lb) 



PAD WEAR LIMIT: 
0.5 mm (0.02 in) 



REPLACE AS A SET 



45 Nm (4.5m-kg, 32 ft- lb) 



MINIMUM DISC THICKNESS: 
7.0 mm {0.28 in) 



MAXIMUM DEFLECTION: 
0.15 mm (0.006 in) 



REPLACE AS A SET 




45 Nm {4.5 m-kg, 32 fflb) 



20 Nm {2.0 m-kg, 14 fflb) 




6-9 



FRONT AND REAR BRAKE 



CHAS 



<3fcfe 



(f) Air bleed screw 
(2) Retaining pin 
(D Dust seal 

(4) Piston seal 

(5) Piston 
©Clirlip 
(7) Shim 



E-fa): 

Install the pad spring with its longer tangs@ in the disc 

rotating direction. 

F-@: 

Be sure to position the shim (T) so that its arrow mark@ 

points in the rotating direction (6) of the disc plate 

rotation. 



\ I REAR CALIPER 




20 Nm (2.0m-kg, 14 ff lb) 



G 


PAD SPRING 














t 


i 
















1 




■ 


i 








■ 


■nua 




warn 







MINIMUM DISC THICKNESS: 
7.0 mm 10.28 in) 



MAXIMUM DEFLECTION: 
0,15 mm (0.006 in) 



6-10 



RONTAND REAR BRAKE 




CALIPER PAD REPLACEMENT 

It is not necessary to disassemble the brake 
caliper and brake hose to replace the brake pads. 
1. Remove: 
• Cover (j) 



2. Remove: 

• Retaining clips (7) 

• Retaining pins (5) 

• Pad spring (§) 



3. Remove: 

• Pads 
NOTE: 



• Replace the pad spring if pad replacement is 
required. 

• Replace the pads as a set if either is found to 
be worn to the wear limit. 






§ 


Wear Limit (a): 
0.5 mm (6.02 in) 



4. Install: 

• Components in above list (steps "3 ~ 1") 

NOTE: 

• FRONT AND REAR BRAKE: 
Install the pad spring with its longer tangs (a) 
facing towards the disc rotating direction. 



6-11 



FRONT AND REAR BRAKE 



CHAS 



<2^> 




• REAR BRAKE ONLY: 
Be sure to position the shim (f) so that its 
arrow mark (a) points in the rotating direction 
(6) of the disc plate rotation. 



CALIPER DISASSEMBLY 

1. Remove: 

• Pads 

Refer to "CALIPER PAD REPLACE- 
MENT" section. 

2. Remove: 

• Brake hose (£) 

Place the open hose end into a container and 
pump the old fluid out carefully. 

3. Remove: 

• Caliper 

CAWKW: 

Never loosen the bridge bolts® on either side 
of the caliper. 



Remove: 

• Dust seals © 

• Piston seals (2) 

• Pistons (D 

By the following removal steps. 



Caliper piston removal steps: 

• Insert a piece of wooden board (4) into the 
caliper to lock the right side piston. 

• Blow compressed air into the tube joint 
opening to force out the left side piston 
from the caliper body. 

• Repeat previous step to force out the right 
side piston from the caliper body. 



6-12 



CHASqN) 



FRONT AND REAR BRAKE 



MASTER CYLINDER DISASSEMBLY 

(t) Master cylinder cap 
(2) Rubber seal 
(DMaster cylinder kit 
4 Copper washer 
(5)Brakejoint 



B [ BRAKE Fl UID TYPF: DOT#3 




rob 

25 Nm ( 2J> rrrkg, J 8 f rib) _ / J>@- 

fj0 



25Nm(2.5m-kg, 18ft. lb) 



25 Nm (2.5m-kg, 18 ft- lb) 



6-13 



FRONT AND REAR BRAKE 



CHAS 



<sfc^ 



(J) Reservoir tank 

(|j Band 

(D Copper washer 

(4j M astEr cylhder kit 

Locknut 

Adjusting rod CForbrake pedalheijhtj 



D BRAKE HOSE ROUTING: 

W hen hstalhg the rear brake hose, 
align the brake ppe {]j w ih the front 
pro^ctbn 2 on the m astEr cylinder. 



'A REAR MASTER CYLTJDER 






6-14 



ICHAS 



dfc^a 



FRONT AND REAR BRAKE 




Front Brake Master Cylinder Disassembly 

NOTE: 

Drain the brake fluid before removing master 
cylinder. 




Dust boot 
(2) Circlip 
(§) Piston 

(4) Piston cups 

(5) Return spring 
(§) Washer 

(7) Seat 

\K\ MASTER CYLINDER KIT (Replace as a set) 

1. Remove: 

• Brake light switch leads (j) 

• Brake lever (2) 

• Lever spring 

2. Disconnect: 

• Brake hose (3) 
Drain the fluid. 



3. Remove: 

• Master cylinder ® 

• Master cylinder cap 



Remove: 

• Dust boot® 

• Circlip (2) 

• Master cylinder kit* 



^ 



6-15 



FRONT AND REAR BRAKE ICHAS 



-~ 




G^) 



Rear Brake Master Cylinder Disassembly 

NOTE: 

Drain the brake fluid before removing master 
cylinder. 

1. Remove: 

• Side cover (right) 

2. Disconnect: 

• Brake hose 



® Spring 

(5) Piston cup 

(f) Piston 

(?) Adjusting rod 

<D Circlip 

(I) Dust boot 

E MASTER CYLINDER KIT (Replace as a set) 

3. Remove: 

• Master cylinder (7) 

• Fluid reservoir tank @ 
Drain the fluid. 

4. Disconnect: 

• Tank hose (§) 



5. Remove: 

• Dust boot ® 

• Circlip (2) 

• Adjusting rod (3) 

• Master cylinder kit ® 
Drain the excess fluid. 



BRAKE INSPECTION AND REPAIR 



Recommended Brake Component Replace- 
ment Schedule: 



Brakepads 



As required 



Piston seal, dust seal 



Every two years 



Brake hoses 



Every four years 



Brakefluid 



Replace only when 
brakes are disassembled 



6-16 



CHAS 



ofc% 



FRONT AND REAR BRAKE 



WARNING: 



AH internal parts should be cleaned in new brake 
fluid only. Do not use solvents will cause seals 
to swell and distort. 

















■ • '■ 




, J 




\_ 




/ 






1 
















1 . Iispect: 
• Brake pads 

Over specified lint 



Replace. 




Wear Limit (a): 
0.5 mm (0.02 in} 



2 . Iispect: 

• Calper piston 

Rust/W ear/D am age -h Replace. 

* Dust seal/fciston seal 
Damage -* Replace. 



WARNING: 



Replace the piston and dust seals whenever a 

calper is disassembled. 

• M aster cylinder kit 

• Master cylinder body 

S cratches /fl ear -* Replace. 

NOTE : 

Clean all passages with new brake fluid. 

(T^j Oil baffle plate 

• Brake hose 

Cracks/W ear/Damage -# Replace. 



^ 



BRAKE REASSEMBLY 



WARNING: 



* AH internal parts should be cleaned in new 
brake fluid only. 

• Internal parts should be lubricated with brake 
fluid when installed. 



KM 



Brake Fluid: 
DOT #3 



"^ 



6-17 



FRONT AND REAR BRAKE 



CHAS 



ofc%) 




Caliper Reassembly 

When assembling the caliper, reverse the disas- 
sembly procedure. Note the following points. 
1. Install: 

• Brake calipers 

• Brake hoses 



ffl 



Brake Caliper: 

45 Nm (4.5 m4<g, 32ft-lb) 

Brake Hose: 

25 Nm (2.5m-kg, 18ft-lb) 



2. Bleed the air completely from the brake 
system. 



Master Cylinder Reassembly 
When assembling the master cylinder, reverse 
the disassembly procedure. Note the following 
points. 
1. Install: 

• Master cylinder kit 



WARNING: 



r- 




Internal parts should be lubricated with brake 
fluid when installed. 

2. Install: 

• Master cylinders (front and rear) 

• Brake hoses 




Front Master Cylinder: 

9Nm (0.9 m-kg, 6.5 ft-lb) 
Rear Master Cylinder: 

23 Nm (2.3 m-kg, 17ft-lb) 
Brake Hose: 

25 Nm (2.5rn-kg, 18 ft-lb) 



CAUTION: 



When installing the rear brake hose, align the 
brake pipe (jT) with the front projection (2) on 
the master cylinder. 



6-18 



CHAS 



ofafe 



FRONT AND REAR BRAKE 



3. Fill: 

* Master cylinders 



*o 



Brake Fluid: 
DOT*3 



4. Bleed the air completely from the brake 
system. 




AIR BLEEDING 



WARNING: 



Bleed the brake system it: 

• The system has been disassembled. 

• A brake hose has been loosened or removed. 

• The brakefluid is very low. 

• The brake operation isfaulty. 

A dangerous loss of braking performance may 
occur if the brake system is not properly bled. 

1. Bleed: 
• Brakefluid 
By the following steps. 



Air bleeding steps: 

a. Add proper brakefluid to the reservoir. 

b. Install the diaphragm. Be careful notto spill 
any fluid or allow the reservoir to overflow. 

c. Connect the clear plastic tube (T) tightly 
to the caliper bleed screw. 

d. Place the other end of the tube into a 
container. 

e. Slowly apply the brake lever or pedal 
several times. 

f. Pull the lever in or push down on the 
pedal. Hold the lever or pedal in position. 

g. Loosen the bleed screw and allow the lever 
or pedal to travel towards its limit. 

h. Tighten the bleed screw when the lever 
or pedal limit has been reached; then release 
the lever or pedal. 






Bleed Screw: 

6 Nm (0.6 m- kg, 4.3 ft- lb) 



i. Repeat steps (e) to (h) until of the air 
bubbles have been removed from the 
system. 



*"> 



^ 



^ 



"> 



6-19 



FRONT AND REAR BRAKE 



CHAS^Sfe 



NOTE: 

If bleeding is difficult, it may be necessary to 
let the brake fluid system stabilize for a few 
hours. Repeat the bleeding procedure when 
the tiny bubbles in the system have disap- 
pered. 



j. Add brake fluid to the level line on the 
reservoir. 




BRAKE DISC INSTALLATION 

1. Install: 
• Brake disc(s) 

NOTE: 



• The brake disc should be installed with the 
arrow mark (T) face outward. 

• The arrow mark (J) on the disc must point 
toward the rotating direction [a' of the wheel. 



2. Tighten: 
• Bolts (disc) 



ffl 



Bolts (Brake Disc): 

20 Nm (2.0 m- kg, 14 ft- lb) 
LOCTITE® 



6-20 



CHAS 



<?fc% 



HYDRAULIC CLUTCH 



HYDRAULIC CLUTCH 

(T) Copper washer 
(2) Master cylinder kit 
(Replace as a set) 



1 Nm (0.1 m -kg, 0.7 f fib) 




9Nm (0.9 m- kg, 6.5 ft- lb) 



25 Nm (2.5m-kg, 18 ff lb) 



% 



IL^-^t) [A J CLUTCH FLUID 




TYPE: DOT #3 



6-21 



HYDRAULIC CLUTCH 



CHASlefc&l 




CLUTCH RELEASE DISASSEMBLY 
1. Remove: 

* Footrest 

• Change pedal 

« Middle gear case cover 

NOTE: 



When removing the middle gear case cover, be 
sure oil does not leak out of the case. 



2. Remove: 

• Clamp (J) 

• Clutch hose (2) 
Drain the fluid. 

• Clutch release assembly < 



3. Remove: 

• Dust seal (f) 

• Piston assembly 

• Spring (3) 



MASTER CYLINDER DISASSEMBLY 
NOTE: 



Drain the clutch fluid before removing master 
cylinder. 



(T)Bush 

©Push rod 

(D Dust boot 

@ Spring 

©Circlip 

©Washer 

©Piston cup 

(D Piston 

(9)Seat 

{fi|) Return spring 

JA Master cylinder kit (Replace as a set) 



6-22 



|CHAS|<2N>| 



HYDRAULIC CLUTCH 




1. Remove: 

• Clutch switch leads (j) 

• Clutch lever© 

• Clutch hose(D 
Drain the fluid. 



2 . Remove : 

• Master cylinder (T) 

• Cap(2) 

Drain the excess fluid. 



. Remove: 

• Dust boot® 

• Push rod (2) 

• Spring (3) 

• Circlip© 

• Master cylinder kit (5) 



^ 



CLUTCH INSPECTION AND REPAIR 



Recommended Clutch Component Replacement 
Schedule: 


Piston seal, dust sel 


Every two years 


Clutch hoses 


Every four years 


Clutch fluid 


Replace only when 
clutch is disassmbled 



1. Inspect: 
• Cylinder body 
Scratches/Wear -> Replace. 

NOTE: 



Clean all passageswith new brake fluid. 

• Clutch hoses 
Cracks/Wear/Damage -> Replace. 



6-23 



HYDRAULIC CLUTCH 



|CHAS|<3fafe| 




3. Inspect: 

• Piston (D 
Scratches/Wear -* 

• Piston seal (5) 
Wear -»■ Replace. 



Replace. 



CLUTCH REASSEMBLY 



WARNING: 



• All internal parts should be cleaned in new 
brake fluid only. 

• Internal parts should be lubricated with brake 
fluid when installed. 



*L? 



Brake Fluid: 
DOT #3 



Clutch Release Reassembly 
When assembling the clutch release, reverse the 
disassembly procedure. Note the following 
points. 
1. Install: 

• Clutch release assembly 

• Clutch hose 



® 



Clutch Release Assembly: 
12Nm(1.2m-kg, 8.7fMb) 

Clutch Hose: 

25Nm(2.5m-kg, 18ft-lb) 



Master Cylinder Reassembly 
When assembling the master cylinder, reverse 
the disassembly procedure. Note the following 
points. 
1. Install: 

■ Master cylinder 

■ Clutch hose 



6-24 



CHAS^sfe 



HYDRAULICCLUTCH 




jeS^iI 


Master Cylinder: 




\iv 


9Nm (0.9 m- 


kg, 6.5 ft- lb) 


-...^^ - 


Clutch Hose: 






25 Nm (2.5 m 


■kg, 18 ft- lb) 



2. Install: 
• Push rod 

o Lever 



NOTE: 

Grease the pivot point (T) 



3. Fill: 

o Master cylinder 



*o 



Brake Fluid: 

DOT #3 



4. Bleed the air completely from the clutch 
system. 

AIR BLEEDING 



WARMING: 



Bleed the clutch system it: 

o The system has been disassembled. 

• A clutch hose has been loosened or removed. 

• The clutch fluid is very low. 

• The clutch operation i s faulty. 




1. Bleed: 
• Clutch fluid (brakefluid) 
By the following steps. 



Air bleeding steps: 

a. Add proper brakefluid to the reservoir. 

b. Install the diaphragm. Be careful not to 
spill any fluid or allow the reservoirto over 
flow. 

c. Connect the clear plastic hose (T) to the 
bleed screw. 

d. Place the other end of the tube into a 
container. 

e. Slowly apply the clutch lever several times. 

f. Pull in the lever and hold it in position. 

g. Loosen the bleed screw and allow the lever 
to travel slowly toward its limit. 

h. Tighten the bleed screw when the lever 
has reached its limit, then release the lever 



6-25 



a 



Bleed Screw: 

6 Nm (0.6 m -kg, 4.3 ft- lb) 



^ 



^ 



HYDRAULT CLUTCH 



CHAS 



Q^3fe 



i. Repeatsteps fe) tD fa) untELalLof the air 
bubbles have been rem oved torn the 

systEm . 

NO TE : 



IE bfeediig is diffbut, ± m ay be necessary 
Id let the cliteh fluid system stabilize for a 
few hours. Repeat the bfeedhg procedure 
when the thy bubbles ±1 the system have 
disappeared. 



j. Add brake fluid to the level Ihe on the 

reservoir. 



6-26 



CHAS 



$y& 



FRONT FORK 



FRONT FORK 

(T) Damper 
(D Air joint 
(D O-ring 
(4)Circlip 
(5) Air valve 
(§) Fork cap 
© O-ring 
(8) Cap bolt 
©Collar 
(fi£ Spring seat 
(jj) Fork spring 
© Rebound spring 



(Q) Cylinder complete 
(Q) Oil lock piece 
(f|) Inner fork tube 
@Guide bush 
(Q) Dust cover 
@ Retaining clip 
©Oil seal 
@ Seal spacer 
@ Slide bush 
@Outer fork tube 
(55) Drain screw 



FORKOIL (EACH): 



CAPACITY: 

451 cm 3 {15.9 Imp oz, 15.3 US oz) 



GRADE: 

Yamaha Fork Oil 10wt or equivalent 



STD. AIR PRESSURE: 

39.2 kPa (0.4 kg/cm 2 , 5.7 psi) 



MIN. TO MAX. AIR PRESSURE: 
39.2-98.1 kPa 

-1.0 kg/cm 2 , 5,7 ~ 14.2 psi) 



FORK SPRING FREE 
LENGTH (LIMIT); 
487.5 mm (19.2 in) 



23 Nm (2.3m-kg, 17ft-lb} 




~" 



^ 



"^ 



40 Nm (4.0m-kg, 29 ff lb) 



6-27 



FRONT FORK 



CHAS 



(2^2) 



REMOVAL 



WARNING: 



r- 




Securely support the motorcycle so itwon't fall 
over when the front wheel and front forks are 
removed. 

1. Remove: 

• Frontwheel 

Refer to "FRONTWHEEL" seciton. 
o Brake calipers 

• Cable holders 

2. Remove: 

• Air valve cap (left) 

• Fork cap 

Depress the valve until all of the air has been 
released. 



3. Loosen: 

o Pinch bolt (steering crown) 
• Cap bolt (f) 
Use the Front Fork Cap Socket (3) (YM- 
01104). 



Loosen: 

• Pinch bolts (under bracket) 



Remove: 

• Rubber damper 

• Air joint bracket (2) 

• Circlip (3) 

o Front fork fs) 



6-28 



CHASofafe 


FRONTFORK 










DISASSEMBLY 

1. Remove: 

• Cap bolt (f) 

Use the Front Fork Cap Socket (YM- 
01104). 

• Collar (2) 

• Spring seat (f) 

• Fork spring (4) 

(5) Inner fork tube 




Remove: 

• Dust cover (T) 

• Retaining clip (2) 

Use a thin screwdriver, and be careful not 
to scratch the inner fork tube. 



Remove: 

• Bolt (cylinder complete) 
Use the Damper Rod Holder (7) (YM- 
01328) and the T-Handle (2) (YU-01326) 
to lock the damper rod. 



Remove: 

• Damper rod (cylinder complete) (T) 

• Rebound spring (2) 



-> 



5. Remove: 

• Innerfork tube 
By the following removal steps. 



"> 



innerfork tube removal steps: 

• Hold fork leg horizontally. 

• Clamp the caliper mounting boss of the outer 
tube securely in a vise with soft jaws. 

• Pull out the inner fork tube from the outer 
tube by forcefully, but carefully, with draw- 
ing the inner tube. 



6-29 



FRONT FORK 



CHAS 



<^!> 



NOTE : 

• Excessive force will damage the oiL seal 
and/6r the bushes, Damaged oil seal and 
bushiig must be lepabed. 

• Avoid bottom rig the riner tube ii the outer 
tube durhg the above procedure, as the oiL 
bck pfece wilL be damaged. 




6. Remove: 

• Oiseal (p 

» Sealspaoer (^) 

• Side bust® 

• Guile bush (?| 
*0 il lock piece (^) 



ISPECTBN 
1 J Inspect: 

• liner fork tube 

ScratcheS/feends ■* Rephae. 



WARNING: 



Do not attem pt to straighten a bent inner fork 
tuba as this may dangerously weaken the tube. 

• Outer folk tube 

Scratches / &ends / Dam age -x Replace. 
■ Foik sprhg 

Over specifed lint ^h Repbce. 




Fork Spring Free Length (Limit): 
487.5 mm (19.2 in) 



2. rispecfc 

•Air jmtbracket 
*Air hose 
Cracks/) am age -m Replace. 

•O-rind (U 

Damage -* Rephce. 



6-30 



FRONTFORK 




3. Inspect: 

• Damper rod 
Wear/Damage^ Replace. 
Contamination ->■ Blow out all oil passages 
with compressed air. 



4. Inspect: 

@0-ring(capbolt)(D 

• Oil lock piece(2) 
Damage -> Replace. 

• Seals 
Wear/Damage -* Replace. 



ASSEMBLY 

Before assembling, clean and inspect all parts 
and replace when necessary. 

NOTE: 

In front fork assembly, be sure to use following 
new parts. Do not reuse them. 

• Slide bush 

• Guide bush 

• Oil seal 

• Dust seal 

1. Install: 

• Rebound spring (j) 

• Damper rod (2) 

Allow the rod to slide slowly down the 
tube until the it protrudes from the 
bottom. 

• Oil lock piece(f) 

Fit oil lock piece over damper rod sticking 
out of the inner fork tube. 

2. Install: 

• Innerfork tube 
Into outer tube. 



6-31 



-~ 



i 



© 




FRONT FORK 



CHAS 



<§3® 




3. Tighten: 

• Bolt (cylinder complete) 
Use the Damper Rod Holder {YM-01 328) 
andtheT-Handle(YU-01326). 



£J 



Bolt (Cylinder Complete): 
40 Nm (4.0 m- kg, 29 ft- lb) 
LOCTITE® 



4. Install: 

*Slide bush® 
Into outer tube. 

Use the Fork Seal Driver Weight (3) (YM- 
33963) and the Adapter (D (YM-33964). 




@inner tube 
(§) Outer tube 

5. Install: 

• Seal spacer (\) 

On top of the slide bush© . 

• Oil seal (D 

Use the Fork Seal Driver Weight © (YM- 
33963) and the Adapter (4) (YM-33964), 
and install with numbered side up. 

(§) inner tube 
(7) Outer tube 

6. Install: 

• Retaining clip ® 

• Dust seal (2) 

Use the Special Tools (D 
(YM-33963, YM-33964) 



(J) inner tube 
@ Outer tube 

7. Fill: 
• Frontfork 



*£} 



Each Fork: 
451 cm 3 (15.9 Impoz, 15.3 USoz) 

Yamaha Fork Oil 10wt or equivalent 
After filling, slowly pump the fork up 
and down to distribute oil. 



6-32 



chas|g£%| 



FRONT FORK 





8. Install: 

• Fork spring (4) 

With smaller pitch side up. 
*Spring seat © 

• Collar© 

• Cap bolt® 

Temporarily tighten the cap bolt. 



INSTALLATION 

1. Install: 

• Front fork(s) 
Into underbracket. 

• Circlip 

Onto innertube. 

Apply a light coat of lithium base grease 

to the O-rings in the air joint bracket. 

• Air joint bracket 

• Rubber damper 
Over inner fork tube. 

2. Tighten: 

• Pinch bolts (underbracket) 
Temporarily tighten the pinch bolts. 

NOTE: 

Position the inner tube end so that it is flush (a) 
with the top of the steering crown. 



3. Tighten: 

• Pinch bolts (under bracket) 



ffi 



Pinch Bolts (Under Bracket): 
23 Nm (2.3 m- kg, 17ft-lb) 



NOTE: 

Do not tighten the pinch bolt (steering crown) 
in this stage. 




4. Tighten: 
• Cap bolt© 
Use the Front Fork Cap Socket © (YM- 
01104). 
*Pinch bolt (steeringcrown) (T) 



£> 



l Cap BoH 

23 Nm (2.3 mkg, 17 ft- lb) 
Pinch Bolts (Steering Crown): 
20 Nm (2.0 mkg, 14ft-lb) 



6-33 



FRONT FORK 



"~ 



Adjust: 

• Front fork air pressure 

Refer to "CHAPTER 2. FRONT FORK 
ADJUSTMENT" section. 
Install: 

• Air valve cap 

• Fork cap 

• Brake calipers 
*Cable holders 

Refer to "FRONT AND REAR BRAKE" 
section. 

• Front wheel 

Refer to "FRONT WHEEL" section. 



6-34 



CHAS 



Q^> 



STEERING HEAD 



STEERING HEAD 



©Steering stem nut 
(2) Lock washer 
®Ring nut (Upper) 
©Washer 



(5) Ring nut (Lower) 

(6) Bearing cover 

(7) Bearing (Upper) 
(D Bearing (Lower) 




($ 



© 1 10 Nm (11 m-kg, 80fflb| | 



20 Nm (2.0m -kg, 14ff lb) ] 



40 Nm (4.0 m-kg, 29 ft- lb) 



A FINGER TIGHTEN 



1. TIGHTEN RINGNUT©: 
50 Nm (5.0 m-kg, 36ff lb) 

2. LOOSEN IT COM PLETY: 

3. RETIGHTEN IT: 
3 Nrn (0.3m-kg, 2.2 ft- lb) 



6-35 



STEERING HEAD 



CHAS 



<2fo2> 



REMOVAL 



WARNING: 




Securely support the motorcycle so there Is 
no danger of it falling over. 

1. Remove: 

• Front wheel 

• Front forks 

2. Remove: 

• Headlight lens unit (f) 

3. Disconnect: 

• All leads (in the headlight body) 



4. Remove: 

*Bolt (headlight body bracket) (f) 
• Emblem© 



5. Remove: 

• Flasher light bracket assembly (T) 



6. Remove: 

• Handlebar holder assembly (T) 



6-36 



STEERUG HEAD 




7. Remove: 

• Biake hose piitiJI 



8J Rem ove: 

• Nut (stEerhg ciown)(J)| 

• Steerhg cmwn (£| 



9 . R em ove : 

• Lock washer (rhg nut) (J| 

• Rhg nut (upper) ($)| 
• W asher (|) 

• R iig nut Cbwer) (4) 



WARNING. 



^ 



Support the under bracket so that tmay not 
fell dow n . 

10. Remove: 

* S teerhg stEm 

• Bearhg cover (j^j 

* Bearhg (upper) (2)| 

• Bearhg (bwer) (§}| 



"> ■ 



"^ 



^ 



6-37 



STEERING HEAD 



CHAS<afc5fe 



INSPECTION 

1. Wash the bearing in a solvent. 

2. Inspect: 

• Bearings 

• Bearing race 
Pitting/Damage^- Replace. 

NOTE: 



Always repalce bearing and race as a set. 



r* 




NSTALLATION 
1. Lubricate: 
• Bearing and races 



S 



Wheel bearing grease 



2. Install: 

• Bearing (lower) (T) 
Onto steering stem. 

• Steering stem (2) 

CAUf 



Hold the steering stem until it is secured. 

• Bearing (upper) (D 

• Ball race cover® 

• Ring nut (lower) (5) 
3. Tighten: 

• Ring nuts (lower and upper) 

By the following tightening steps. 



Ring nutstightening steps: 

• Install the ring nut (lower)@. 

NOTE: 



The tapered side of ring nut must face down- 
ward. 



• Tighten the ring nut (5) using the Ring Nut 
Wrench (YU-33975). 



ffl 



Ring Nut (5) (Initial Tightening) 
50 Nm (5.0m-kg, 36ft- lb) 



• Loosen the ring nut (5) completely and 
retighten itto specification. 



WARNING: 



Do not over-tightening. 



« 



Ring Nut© (Final Tightening) 
3Nm (0.3m -kg, 2.2 ft- lb) 



6-38 



CHAS 



Q^> 



STEERING HEAD 




@Checkthe steering stem by turning it lock 
to lock. If there is any binding, remove the 
steering stem assembly and inspect the 
steering bearings (T), (f). 

• Install the washer (6) . 

• Install the ring nut (upper)® . 

NOTE: 



The tapered side of ring nut must face down- 
ward. 



• Finger tighten the ring nut (7), then align 
the slots of both ring nuts. If not aligned, 
hold the lower ring nut (5) and tighten the 
other until they are aligned. 

• Install the lock washer® . 



NOTE: 

Make sure the lock washer tab is placed in the 
slots. 



• Install the steering crown (9) and tighten 
the steering stem nut (Q} to specification. 



€i 



Nut (Steering Stem): 

110 Nm (11.0 m-kg, 80fMb) 



• Tighten the pinch bolts to specification. 



© 



Pinch Bolt (Steering Crown): 
20 Nm (2.0 m-kg, 14ft-lb) 



5. Install: 

• Components in aforementioned list (steps 
"7-1") 



fH 



Handlebar Lower Holder: 
40 Nm (4.0 m-kg, 29 ft- lb) 



6-39 



REAR SHOCK ABSORBER 



CHAS|(2fc5fc| 



REAR SHOCK ABSORBER 

(J) Rear shock absorber assembly 



20 Nm (2.0m -kg, 14 ft- lb) 



'© 



30 Nm <3.0m-kg, 22 ft- lb) 



SPRING PRELOAD POSITION 
(STANDARD): 1 



DAMPING POSITION 
(STANDARD): 1 



20 Nm (2.0m «kg, 14ft- lb) 




30 Nm (3.0m-kg, 22 ff lb) 



6-40 



|CHAS|<£% 



REAR SHOCK ABSORBER 




Wff/9 




REMOVAL 

1. Remove: 

• Bolt (shock absorber top) (T) 

• Special washer (f) 

• Nut (shock absorber bottom) (§) 
*Plain washer (4) 



^ 



2. Pull out the shock absorber top, and turn 
the shock absorber clockwise. 

3. Remove: 

• Rear shock absorber 



INSPECTION 

1. Inspect: 

• Shock absorber rod 

Bends/Damage — Replace the shock 
absorber assembly. 
*Shock absorber 
Oil leakes -*■ Replace the shock absorber 
assembly. 

• Spring 

Fatigue -* Replace the shock absorber 

assembly. 

Move the spring up and down. 



"> 



INSTALLATION 

When installing the rear shock absorber, reverse 

the removal procedure. Note the following 

points. 

1. Apply: 
# Lithium base grease 

To the pivot points. 



6-41 



REAR SHOCK ABSORBER 



CHAS 



<afc% 




2. Install: 

• Rear shock absorber 



NOTE: 

The rear shock absorber should be installed so 
that the damping match mark (Don the shock 
absorber faces outward© . 

3. Tighten: 

• Bolt (shock absorber top) 

• Nut (shock absorber bottom) 



ffl 



Bolt (Shock Absorber Top): 
20 Nm (2.0 m- kg, 14ft- lb) 

Nut (Shock Absorber Bottom): 
30 Nm (3. Cm- kg, 22 ft- lb) 



4. Adjust: 

• Spring preload 

• Damping force 

Refer to "CHAPTER 2. REAR SHOCK 
ABSORBER ADJUSTMENT" section. 



6-42 



CHAS 



<sfc% 



SWINGARM 



SWINGARM 

(T) Locknut 

(2) Pivot shaft (right) 

(D Collar 

(4) Oil seal 

(5) Taper roller bearing 
© Pivot shaft (left) 

(7) Lock washer 

(8) Collar 
(D Oil seal 

(j^ Taper roller bearing 
(Q) Rubber boot 



J20Nm (2.0m.kg, 14ft.lb)] 




I 100 Nm ("lO.Om-kg, 72fflb) 



& 



~N 



^ 



~> 



^ 



6-43 



SWINGARM 



CHAS 



<$3& 




FREE PLAY INSPECTION 

1 . Remove: 

• Rear wheel 

• Rear shock absorbers 

2. Check: 

• Swingarm (side play) 

Side play -► Replace taper roller bearings 
and collars. 

Move the swingarm from side to side. 
There should be no noticeable side play. 

3. Check: 

• Swingarm (vertical movement) 
Tightness/Binding/Rough spots -+ Replace 
bearings. 

Move the swingarm up and down. 



REMOVAL 

1. Remove: 

• Rear wheel 

• Rear shock absorbers 

• Pivot shaft caps 

2. Flatten: 

• Lock washer tab 
Use a blunt chisel. 




3. Remove: 

• Pivot shaft (left)© 

• Lock washer © 



4. Remove: 

• Nut® 

• Pivot shaft (right)© 



6-44 



SWINGARM 




5. Remove: 
• Rubber boot 
*Bolts (muffler)® 



6. Remove: 
• Swingarm ® 
Push down the muffler. 



7. Remove: 
• Final gear assembly 



INSPECTION 

1. Wash the bearings in a solvent. 

2. Inspect: 

• Bearings (race/rollers) ® 
Pitting/Damage -* Replace. 

• Oil seals ® 

• Collars® 
Damage-* Replace. 



3. Inspect: 



• Rubber boot 
Damage-* Replace. 



6-45 



SWINGARM 



<sfc% 



CHAS 



-~ 




INSTALLATION 

When installing the swingarm, reverse the re- 
moval steps. Note the following points. 
1. Lubricate: 

• Bearing 

• Oil seals 



^ 



Lithium Base Waterproof Wheel 
Bearing Grease 



2. Install: 

• Swingarm 

• Pivot shafts 

3. Tighten: 

• Pivot shafts 

By the following tightening steps. 



Pivot shaft tightening steps: 
• Tighten the pivot shaft (left)® to specifi- 
cation, 



m 



Pivot Shaft (Left): 

100Nm (10.0m -kg, 72 ft- lb) 



• Tighten the pivot shaft (right) (D until h 
contacts the collar (5). 



/oT\| Pivot Shaft (Right): 

^JM 6 Nm (0.6 m -kg, 4.3 ft- lb) 



• Tighten nut (right pivot shaft)© to specifi- 
cation. 



£S 



Nut (Right Pivot Shaft): 

100 Nm (10.0 m -kg, 72 ft- lb) 



• Bend the lock washer tab (D along the nut 
flat. 



4. Apply: 

• Sealant (Quick Gasket@) 
(ACC-1 1001-05-01) 

To the mating surfaces of both case halves. 

5, Install: 

• Final gear assembly 




Nuts (Final Gear Case): 
42 Nm (4.2m -kg, 30 ft- lb) 



6. Check: 

• Swingarm (side play) 

• Swingarm (vertical movement) 

Refer to "FREE PLAY INSPECTION" 
section, 



6-46 



r 



CHAS 



ofcfa 



SHAFT DRIVE 



SHAFT DRIVE 



® 

® 



1$ 



Dust cover © Bearing 

Bearing housing (f§) Drive pinion gear 

Ring gear Stopper shim (g) Final drive gear shim 

Ring gear stopper QJ) Bearing 



O-ring 

Oil seal 

Ring gear shim 

Bearing 

Ring gear 

Thrust washer 

Bearing 

Oil seal 

Collar 

Bearing 



QJ) Bearing retainer 

® O-ring 

©Oil seal 

@ Coupling gear 

@ Spring 

@Circlip 

© Drive shaft 

® Oil seal 

@! Washer 

@ Circlip 



<|f) Bearing 
@) Circlip 
(§])Universal joint 



A FINAL GEAROIL: 



23 Nm (2.3nvkg, 17ff lb) 



40 Nm (4.0 m-kg, 29 ft- lb) 



E KINDS: 6 



9Nm (0.9 m-kg, 6.5 ff lb) 



CAPACITY: 

0.2 L (0.18 Imp qt, 0.21 US qt) 



TYPE: 

SAE 80 API GL-4 HYPOID GEAR OIL 



GEAR LASH: 

0.1 - 0.2 mm (0.004 - 0.008 in) 



110Nm 

(11.0 m-kg, SOfflb) 




23 Nm 

(2.3 m-kg, 17 ff lb) 



110 Nm (11.0 m-kg, 80 ff lb) 



23 Nm (2.3 m-kg, 17 ft-lb} 



42 Nm (4.2 m-kg, 30 ff lb) 



6-47 



SHAFT DRIVE 



CHAS 



Q^% 



/— 



TROUBLESHOOTING 

The following conditions may indicate damaged shaft drive components: 



A Symptoms 


B Possible Causes 


1. A pronounced hesitation or "jerky" movement 
during acceleration, deceleration, or sustained 
speed. (This must not be confusewith engine 
surging or tansmission characteristics.) 

2. A "rolling rumble" noticeable at low speed; a 
high-piched whine; a "clunk"from a shaft 
drive component or area. 

3. A locked-up condition of the shaft drive 
mechanism; no power transmitted from 
engine to rear wheel. 


A. Bearing damage. 

B. Impropergear lash. 

C. Gear tooth damage. 

D. Broken drive shaft. 

E. Broken gear teeth. 

F. Seizure due to lack of lubrication. 

G. Small foreign object lodged between moving 
parts. 



NOTE: 

Areas A, B, and C above may be extremely dif- 
ficult to diagnose. The symptoms are quite 
subtle and difficult to distinguish from normal 
motorcycle operating noise. If there is reason 
to believe these components are damaged, 
remove the components for specific inspection. 



6-48 



CHAS 



ofcfe 



SHAFT DRIVE 



Inspection Notes 
1. Inrestigateany unusual noises 



The following "Noises" may indicate a 
mechanical defect: 

a. A "rolling rumble" noise during coasting, 
acceleration, or deceleration. The noise 
increases with rear wheel speed, but it does 
not increase with higher engine or trans- 
mission speeds. 

Diagnosis: Possible wheel bearing damage. 

b. A "whining" noise that varies with accele- 
ration and deceleration. 

Diagnosis: Possible incorrect reassembly, 
too-little gear lash. 

CAUTION: 



Too-little gear lash is extremely destructive 
to the gear teeth. If a test ride following 
reassembly indicates this condition, stop 
riding immediatelyto minimize gear damage. 



c. A slight "thunk" evident at low speed 
operation. This noise must be distinguished 
from normal motorcycle operation. 
Diagnosis: Possible broken gear teeth. 



WARNING: 



Stop riding immediately if broken gear teeth 
are suspected. This condition could result in 
a locking-up of the shaft drive assembly, 
causing loss of control of the dike and possible 
injury to the rider. 



2. Inspect: 
• Drained oil 
Drain plug shows large amount of metal. 
Particles -> Check bearing fur seizure. 



NOTE: 

A small amount of metal particles in the oil is 
normal. 



^ 



6-49 



SHAFT DRIVE 



CHAS]<3fcfe] 



3. Inspect: 
• Oil leakage 
By the following inspection steps. 









3^H 






y£i^ 


BFj 


j§^v3 


®Thu 


-KT^® 








V ( 


\ 


CD I 








qJ ® 






~7® 


®\\5t 


(rl 


L--® 




3c£_T^ll 


r^l 


-i 




1 


. 






1 If" T 


"""v ? (L^l 


V~daJk 



Oil leakage inspection steps: 

oClean the entire motorcycle thoroughly, 
then dry it. 

• Apply a leak-localizing compound or dry 

powder spray to the shaft drive. 

• Road test the motorcycle for the distance 
necessary to locate the leak, 



Leakage 



Damage - 
©Oil seat 
(3) Forward 



Inspect component housing, 
gasket, and/or seal for damage. 
Replace component. 



NOTE: 

• An apparent oil leak on a new or nearly 
new motorcycle may be the result of a 
rest-preventative coating or excessive seal 
lubrication. 

• Always clean the motorcycle and recheck 
the suspected location of an apparent 
leakage. 



6-50 



CHAS 



<*fc5fc 



©I SHAFT DRIVE 



Troubleshooting Chart 

When basic conditions "a" and "b" above exist, check the following points: 



Elevate and spin the front wheel. Feel 
for wheel bearing damage. 



Yes 



£ 




Replace the wheel bearing. 

(Refer to "CHAPTER 5. FRONT 

WHEEL") 



Check the rear wheel. Feel for bearing 
damage. 





Rear wheel bearings and shaft drive 
bearings probably not damaged. Repeat 
test or remove individual components. 



Remove the rear wheel. Check for wheel 
bearing damage. 



Yes 



> 




Replace the rear wheel bearing. 
(Referto "CHAPTER 5. REAR WHEEL" 
section). 



Remove the drive shaft components. 



~> 



6-51 



SHAFT DRIVE 



CHAS 



<£y® 



1.5 mm (0.06in) 




14 mm 
(0.55m: 



FINAL DRIVE GEAR 
Gear Lash Measurement 

1. Secure the gear case in a vise or other 
support. 

2. Remove: 

• Drain plug 
Drain the oil. 

3. Install: 

• A specified bolt(T) 
Into the drain plug hole. 

4. Finger tighten the bolt until it holds the 
ring gear. 

NOTE: 

Do not over tighten the bolt; finger-tight is 
sufficient. 




5. Attach: 

• Gear Lash Measurement Tool (T) (YM- 
01230) 

• Dial Gauge© (YU-03097) 
(3) Position mark 

6. Measure: 

• Gear lash 

Gently rotate the gear coupling from 
engagement to engagement. 
Over specified limit -> Adjust. 




Final Gear Lash: 
0.10 - 0.20 mm (0.004 _ 0.008 in) 



NOTE: 

Measure the gear lash at 4 positions. Rotate the 
shaft 90" each time. 




Gear Lash Adjustment 
1. Remove: 

• Nuts (bearing housing) 

• Bolts (bearing housing) 

NOTE: 



Working in a crisscross pattern, loosen nut 1/4 
turn each. Remove them after all are loosened. 



6-52 



CHAS 



<2^% 



SHAFT DRIVE 




2 . R em ove : 

• Beamg houshg (J) 

• Dust cover (5) 

• Rhg gear 

• Shin (s)(D 

• Thrust washei(4) 

3 . Adjist: 

• G ear hsh 

By the folbwiig adjistm entstEps. 



Gear lash adjustment steps: 
• Select the suiabfe shin s and thrust washer r 
by the fclbw iig chart. 



Too -little gear lash -H 

Reduce shin thickness. 

Too-laige gear lash -h 

Increase shin thickness. 



To Add or Reduce Ring Gear Shin 
Thickness 



Increase by m ore 

than 01 mm (0.004 in) 



Reduce by m ore 

than 01 mm (0.004 in) 



1 



Reduce thrust washer 
thickness by 0.1 mm (0.004 in} 
for every 0.1 mm of ring 

gear shin increase. 



Reverse 
procedure 




Ring Gear Shim 



Thickness (mm) 



0.25 
0.40 



0.30 
0.45 



0.35 
0.50 




Thrust W asher 



Thickness frn m 



1.4 

1.7 
2 .0 
2 3 



1.5 

1 .8 

2 .1 



1.6 
1.9 
2 2 



^ 




Ring Gear Stopper Clearance Measurement 
1 . R em ove : 

• Beamg houshg wih rhg gear 
Refer to 'Gear Lash Adjistm ent' sectbn. 



^> 



6-53 



r- 



SHAFT DRIVE 



CHAS 



<£y& 




2. Measure: 

• Ring gear stopper clearance© 
Use the Feeler Gauge 0. 
Out of specification -* Adjust. 



M 



Ring Gear Stopper Clearance© : 
0.30-0.60 mm (0.012- 0.024 in) 



(2) Ring gear stopper 
(D Ringgear 

3. Install: 

• Bearing housing with ring gear 



Ring Gear Stopper Clearance Adjustment 

1. Remove: 

• Ringgear® 

• Ring gear stopper (2) 

• Shim(s) (D 

(4) Bearing housing 
fj Left-hand-threads 

2. Select: 

• Suitable shim(s) 

By the following chart. 



% 




Shim 


ThLc 
I 


kna&s (mm) 


0.10 0.15 
0.40 0.50 



3. Install: 
• Components in above list (step"1") 



ffl 



Ring Gear Stopper: 
9Nm (0.9 m -kg, 6.5 ft- lb) 
LOCTITE® 



4. Measure: 

• Ring gear stopper clearance 



6-54 



CHAS 



G&5& 



SHAFT DRIVE 




Final Drive Gear Disassembly 
1 . Remove: 

• Nuts (bearing housing) 

• Bolts (bearing housing) 



NOTE: 

Working in a crisscross pattern, loosen nut 1/4 
turn each, Remove them after all loosened. 



2. Remove: 

• Bearing housing (J) 

• Dust cover (§) 

• Shim(s) 

• Thrust washer 



Remove: 

• Self-locking nut (coupling gear) 

Use a Final Drive Shaft Holder (T) (YM- 
,01229). 

• Coupling gear 



4. Remove: 

• Bearing retainer (final drive shaft) 
Use a Final Drive Shaft Bearing Retainer {J) 
(YM-04050). 



CAUTION: 

Finaldrive-shaft-bearing-retainer has left-hand 
threads. Turn retainer clockwise to loosen it. 

• Final drive shaft assembly 
Tap lightly on the final drive shaft end 
with a soft hammer. 



CAUTION: 



Final drive shaft removal should be performed 
only if gearing replacement is necessary. Do not 
reuse bearings or races after removal. 



6-55 



SHAFT DRIVE 



|CHAS|<2N>| 




*~ 



Bearing Removal and Reassembly 

1. Remove: 
*Guide collar (D 

• Oil seal (D 

• Roller bearing (3) 

Use a suitable press tool (4) and an appro- 
priate support for the main housing. 

2. Inspect: 

• Roller bearing 
Damage -*■ Replace. 

NOTE: 

Reuse of roller bearing OK, but Yamaha recom- 
mends installation of new bearing. Do not 
reuse the oil seal. 

3. Remove: 

• Final drive shaft roller bearing (f) 
By the following removal steps. 



Final drive shaft roller bearing removal steps: 

• Heatthe bare housingto 150°C (302"F) 

• Remove the roller bearing outer race with an 
appropriately shaped punch (6). 

*Remove the inner race from the final drive 
shaft. 



NOTE: 

The removal of the final drive shaft roller 
bearing is difficult and seldom necessary. 



4. Install: 

• Rear final drive shaft roller bearing (new) 
By the following installation steps. 



Final drive shaft roller bearing installation 
steps: 

• Heatthe bare bearingto 150°C (302°F) 

• Install the roller bearing outer race using the 
proper adapted. 

• Install the inner race onto the drive shaft. 



6-56 



chas|g^)| 



SHAFT DRIVE 





. Install: 

• Guide collar© 

• Oil seal (new)(2) 

• Roller bearing (outer race) (§) 

Use a suitable press tool (4) and a press to 
install the above components into the 
main housing. 



Final Drive/Ring Gear Positioning 
NOTE: 



Gear positioning is necessary when any of the 

following parts are replaced: 

o Final gear case 

o Ring gear bearing housing 

• Beari.ng(s) 




1 . Select: 

• Final drive gear shim (f) 

• Ring gear shim (2) 

By the following selection steps. 



Final drive/ring gear shim selection steps: 

• Position final drive shaft gear and ring gear 
by using shims (f) and (2) with their re- 
spective thicknesses calculated from infor- 
mation marked on final gear case and drive 
gear end. 

J) Shim thickness "A" 
^) Shim thickness "B" 
(D Thrust washer 

• To find shim thickness "A" use following 
formula: 



Final Drive Gear Shim Thickness: 
A = a-b 



^ 



^ 



"> 



6-57 



SHAFT DRIVE 



CHAS 



<jfc% 




Wheie: 

a = a numeral (asualy a decinal number) on 
the gear is either added to or subtracted 
from "84" . 
b = a numeral on the gear case fie. 83 50) 
Sxamph: 
1 ) IE final drive shaft gear is m arked "+01" 

., . "a" is 8401. 
i!) IE the gear case is m arked "83 .50" , . , 
"b" is 83S0. 
A = 84.01 -83 50 
= 051 
£0 Therefore, shin thrkness is 051 mm . 

Shin sites are supplied ±i &Ibwhg thick- 
nesses: 




Thickness 
(mm) 



Final Drive Gear Shim 



0.15 
0.40 
0.60 



0.30 
0.50 



Because shins can any be selected ±i 0D5 > 
mm hcrenente, round off hundredths dgitt 
and select approprate shin (s). 



Hundredths 



0,1,2 



3 . 4 . 5 .6 . 7 



Round valie 



8.9 



10 



S. the example above, the calculated shim 
thickness is 51 mm . The chart instructs 
you, however, to round off the 1 to 0. 
Thus you should use a 050 mm shin . 
• To find shim thickness use following;] 

formula: 



Ring Gear Shin Thickness: 
B =c+d-(e+f) 



CHAS 



C2^% 



SHAFT DRIVE 




Where: 

c =numeral on gear case (i.e. 45.52) 

d =numeral (usually a decimal number) on 

outside of ring gear bearing housing and 

added to 3. 
e =numeral (usually a decimal number) on 

inside of ring gear either added to or 

subtracted from 35.40. 
f = bearing thickness (consideredconstant). 



m 



Bearing Thickness "f"= 13.00 mm 



Example: 

1) If gear case is marked "45.52" . . . "c" is 
45.52. 

2) If ring gear bearing housing is marked 
"35" . . . "d" is 0.35 +3 = 3.35. 

3) If ring gear is marked "+01" . . . "e" is 
35.40 + 0.01 =35.41. 

4) "f" is 13.00. 

= c + d - (e + f) 

= 45.52 +3.35 - (35.41 + 13.00) 

= 48.87 - (48.41) 

= 0.46 

5) Therefore, shim thickness is 0.46 mm. 
Shim sizes are supplied in following thick- 
ness: 



3 



Ring Gear Shim 



Thickness (mm) 



0.25 
0.40 



0.30 0.35 
0.45 0.50 



Because shims can only be selected in 0.05 
mm increments, round off hundredths 
digit and select appropriate shim(s). 



~> 



6-59 



SHAFT DRIVE 



CHASofafc 



Hundredths 



Round value 



I 



1 0, 1 , 2 


I 


3, 4, 5, 6, 7 


5 


8,9 


10 



In the example above, the calculated shim 
thickness is 0.46 mm. The chart instructs 
you, however, to round off the 6 to 5. 
Thus you should use a 0.45mm shims. 




2. Install: 

*Shims (propersize as calculated) 

• Final drive shaft assembly 

• Bearing retainer (final drive shaft) 

Use a Final Drive Shaft Bearing Retainer 
Wrench (YM-04050). 



NOTE: 

The bearing retainer has left-hand threads; turn 
retainer counterclockwise to tighten it. 



m 



Bearing Retainer: 

110Nm (11.0m-kg,80ft-lb) 



3. Install: 

• Coupling gear 

• Self-locking nut (coupling gear) 
Use a Final Drive Shaft Holder 
01229). 



(YM- 



£j 



Self-locking Nut {Coupling Gear) 
110Nm(11.0nvkg, 80 ft- lb) 
LOCTITE® 



4. Install: 

• Ring gear assembly (without thrust washer) 

5. Adjust: 

• Gear lash 

Refer to "Gear Lash Measurement and 
Adjustment" section. 

6. Measure/Select: 

• Ring gear thrust clearance 

By the following measurement and selec- 
tion steps. 



6-60 



CHAS 



<gfcfe 



SHAFT DRIVE 



^ -\ 


IJ> 




!\ 




s. / oW 




ftli 




ss^/y^d 


(«=^gg^ 




ssa <aj 



Thrust clearance measurement steps: 

o Removethe ring gear assembly. 

• Place four pieces of Plastigage® between 

originally fitted thrust washer and ringgear. 
o Install the ring gear assembly and tighten 

the bolts and nutsto specification. 



Bolts (Bearing Housing): 
40 Nm (4.0 m -kg, 29 ft- lb) 

Nuts (Bearing Housing): 
23 Nm (2.3m -kg, 17 ft- lb) 




NOTE: 

Do not turn the shaft drive and ring gear 
when measuring clearance with Plastigage®. 



• Remove the ring gear assembly. 

• Measure the thrust clearance. Calculate 
width of flattened Plastigage®® . 




Ring Gear Thrust Clearance: 

0.1 ~ 0.2 mm (0.004 ~ 0.008 in) 



o If the correct clearance, install the ringgear 
assembly. 

• If the out of specification, select the correct 
washer. 

Thrustwasher selection steps: 

• Select the suitable thrust washer by the 
following chart. 



Thrust Washer 



Thickness (mm) 



1.4 
1.7 
2.0 
2.3 



1.5 1.6 
1.8 1.9 
2.1 2.2 



o Repeat measurement steps until the ring 
gear thrust clearance is within the specified 
limits. 



a 



Ring Gear Thrust Clearance: 

0.1 ~ 0.2 mm (0.004" 0.008 in) 



6-6 \ 



SHAFT DRIVE 




CHAS 



<£% 



DRIVE SHAFT 
Removal 
1. Remove: 

• Rear wheel 

• Final gear assembly 

• Drive shaft (D 



Inspection 
1. Inspect: 
• Drive shaft splines 
Wear/Damage -> Replace. 



Installation 

When installing the dirve shaft, reverse the 
removal procedure. Note the following points. 
1. Lubricate: 
• Shaft splines 



H 



Molybdenum Disulfide Grease 



2. Install: 
• Drive shaft 



NOTE: 

Before installing, first set the universal joint in 
place on the middle case side. 

3. Apply: 

*Sealant (Quick Gasket®) 
(ACC-1 1001-05-01) 
To the mating surfaces of both case halves. 

4. Tighten: 

• Nuts (final gear case) 



£]| 



Nuts (Final Gear Case) : 
42 Nm (4.2m- kg, 30 ft- lb) 



6-62 




CHAPTER 7. 
ELECTRICAL 

VMX12N/NC CIRCUIT DIAGRAM 7-1 

ELECTRICAL COMPONENTS 7-3 

ELECTRIC STARTING SYSTEM 7-5 

CIRCUIT DIAGRAM 7-6 

TROUBLESHOOTING 7-7 

STARTING CIRCUIT CUT-OFF SYSTEM 7-9 

STARTER MOTOR TEST 7-10 

BATTERY INSPECTION 7-13 

STARTER RELAY TEST 7-13 

STARTING CIRCUIT CUT-OFF RELAY TEST 7-14 

SIDESTAND RELAY TEST 7-14 

DIODE TEST 7-15 

NEUTRAL SWITCH TEST 7-16 

SIDESTAND SWITCH TEST 7-16 

CHARGINGSYSTEM 7-17 

CIRCUIT DIAGRAM 7-17 

TROUBLESHOOTING 7-18 

CHARGING VOLTAGE TEST 7-20 

BATTERY INSPECTION 7-20 

STATOR COIL RESISTANCE TEST 7-20 

RECTIFIER TEST 7-21 

IGNITION SYSTEM 7.23 

CIRCUIT DIAGRAM 7-23 

TROUBLESHOOTING 7-25 

DESCRIPTION 7-27 

OPERATION 7-27 

IGNITION SPARK GAP TEST 7-28 

IGNITION COIL RESISTANCE TEST 7-28 

PICKUP COIL RESISTANCE TEST 7 ' 29 

PRESSURE SENSOR 7-29 

LIGHTING SYSTEM 7-31 

CIRCUITDIAGRAM 7-31 

LIGHTING TESTS AND CHECKS 7 " 33 

SIGNAL SYSTEM 7-37 

CIRCUIT DIAGRAM 7-37 

SIGNAL SYSTEM TESTS AND CHECKS 7 " 39 

01 L LEVEL GAUGE TEST 7-40 

REED SWITCH TEST 7-41 

SELF-CANCELLING FLASHER SYSTEM TEST 7-41 

SWITCHESTEST 7-43 




COOLING SYSTEM 7-45 

CIRCUIT DIAGRAM 7-45 

TROUBLESHOOTING 7-47 

ELECTRIC FAN AND THERMOSTATIC SWITCH 7-48 

THERMO-UNIT AND THERMOMETER 7-49 

FUEL PUMP SYSTEM 7-51 

CIRCUIT DIAGRAM 7-51 

FUEL PUMP CIRCUIT OPERATION 7-53 

TROUBLESHOOTING 7-54 

"FUEL" (RESERVE) SWITCH TEST 7-57 

FUEL PUMP RELAY TEST 7-57 

FUEL PUMP TEST 7-57 

FUELSENDER UNITTEST 7-58 

V-BOOST SYSTEM 7-59 

CIRCUIT DIAGRAM 7-59 

V-BOOST SYSTEM 7-61 

TROUBLESHOOTING 7-64 

SERVO MOTOR TEST 7-66 



""> 



ELEC 



CIRCUIT DIAGRAM 



ELECTRICAL 

VMX12N/NC CIRCUIT DIAGRAM 



35 



R/W 



R/B 



T i - 

R/W R/W 




© 



OFF 



7W 



B/Y L/Y 



B/W- 



6/Y Sb L/Y 



V 

B 
1 



© 



R/W~*-R/W- 

-B/R- 

-B/Y- 



© 



-Gy- 
-Y- 



-w 



SJTtK 

u^lv/G J? R/G 



"oJ 



R/W 



-Br- 



Mlai 



R — 



© 



, — Br— J 



ki 



a 



— R-OS^SfcBJ 



-Sb — 
-B/Y- 
-R/B- 
-Gy — 

-L 



6 Gy WR W/G l iW 
Lj Lj LJ U L/bI © L 
©Vy G Br 



© 



© 



"J® 

X 



® 






© 



-Br- 



r _r^X7x 

Br Br B/Y 



-B^- 



© 



I 



| 



V/R Br/W 



R d l S _ i 



w 



Br 
L 



Ch 



oo 



Br_ 

/pa 
w 



oo 



oo 



oo 



© 



L/W 

<i 



OO 



oo 



L/W 




r 

Ch Ch 



r&h 



r 



h 



©9 




Dg Dg 

r 

L 






CD @-± 

-Br— f^-G/R- ^^ -, 



!• 



.►Br 



-Gy- 



k © 



© 



Br— (o) — P— O O— j_ 

1 G ^-i © ~ 

i^-Br— (§)— -W|0 O^ 

— l/w — —14-1 © ' 



Sb 1 



Br Br 

Br 6 I a 6 



®I_J 



L Br- 



Br 



© 



R/Y 



<&> 



L 



L/B- 



© P © 




© 









7-1 



CIRCUIT DIAGRAM 



ELEC = 



d) 

® 

(D 

® 
® 

(9) 
0) 






© 



Ignition coil #1 
Spark plug #1 
Ignition coil #2 
Spark plug #2 
Ignition coil #3 
Spark plug #3 
Ignition coil #4 
Spark plug 34 

Temperature meter 

Thermo-unit 

Tachometer 

Horn 

"HORN" switch 

"FUEL" indicator light 

Fuel sender unit 

"OIL LEVEL" warning indicator light 

Oil level gauge 

"NEUTRAL" indicator light 

Neutral switch 

Front brake switch 

Rear brake switch 

"LIGHTS" (Dimmer) switch 

Headlight 

"HIGH BEAM" indicator light 

Meter light 

Tail/brake light 

Fuse (HEAD) 

Fuse (SIGNAL) 

Relay unit 

Starting circuit cut-off relay 

Flasher relay 



(§f) Cancellingunit 

<§i& Starter switch 

@ "TURN" switch 

(|f) "TURN" indicator light 

@) Parking/Running light 

@ Flasher light 

@ Reed switch 

§ Thermo switch 
Electric fan 

@ Fuse 

§AC Magneto 
Rectifier with regulator 
@ Main fuse 

(@ Battery 

@ Starter motor 

@ Starter relay 

@ Main-switch 

@ Fuse (IGNITION) 

© "ENGINE STOP" switch 

@ V-boost valve control unit 

@ Servo motor 

!§§) Clutch switch 

@J Diode 

tSidestand switch 
Sidestand relay 
@ Pressure sensor 
@ Ignitorunit 
@ Pick-up coil (#1~ #4) 
(§) "FUEL" (RESERVE) switch 
@ Fuel pump relay 
@ Fuel pump 



COLOR CODE 

B Black 

L Blue 

O Orange 

G Green 

R Red 

P Pink 

Y Yellow 

W White 

Br Brown 

Dg Dark green 

Ch Chocolate 

Sb Sky blue 

Gy Gray 

G/R Green/Red 

G/Y Green/Yellow 

B/R Black/Red 

B/W Black/White 

B/Y Black/Yellow 

L/Y Blue/Yellow 

LIB Blue/Black 

LAN Blue/White 

R/W Red/White 

RIG Red/Green 

RIB Red/Black 

R/Y Red/Yellow 

W/R White/ Red 

WIG White/Green 

W/B White/Black 

Y/R Yellow/Red 

Y/L Yellow/Blue 

Br/W Brown/White 



7-2 



ELEC M 



ELECTRICAL COMPONENTS 



ELECTRICAL COMPONENTS (1) 

(D TCI unit 

(D Pressure sensor 

(I) Ignition coil (#1 &#3) 

® Neutral switch 

® Oil level gauge 

© Ignition coil (#2&#4) 

(Z) Thermostatic switch 

(D Thermo-unit 



SPECIFICATIONS 


RESISTANCE 


IGNITION COIL: 




PRIMARY 


2.752+ 10% 


SECONDARY 


13.2kft±20% 


PICK-UP COIL: 


lion + 15% 




^ 



~" 



7-3 



ELECTRICAL COMPONENTS 



ELECTRICAL COMPONENTS (2) 



(T) Starter relay 
@ Main fuse 

S Battery 
Rectifier with regulator 
(§) Sidestand switch 
(§) Rear brake switch 
(7) Horn 
(§) Relay unit 
(D Sidestand relay 
@ V-boost valve control unit 
<Jj) Fuel pump relay 



(g) Diode 

(f§) Main switch 

(Q) Wire harness 



_—- -<D 




A 


BATTERY: 


B 


CAPACITY: 12V, 16AH 


C 


SPECIFIC GRAVITY: 
1,280 



7-4 



ELEC 



ELECTRIC STARTING SYSTEM 



ELECTRIC STARTING SYSTEM 
CIRCUIT DIAGRAM 



r± 



I 1 



© 



R/W 
6 |© 



® 



@ 



ON 



OFF 



Br 



ooo 



Br 



-i — r 

R/W R/W 



PTftJ 



B/Y L/Y 



® 



"I 



■B/W- 



R/W-*-R/W' 



B/Y Sb L/Y 



A 

? 

B 
1 



© 



-B/R- 
-B/Y- 



@> 



-Gy- 
-Y- 



FSJlTTr 



35 



R/W 



r 

O Gy W/R 

Lrfertr 



-Br- 



[m)@ 



R — 






i — Br — i 



@ 
-R-CTN-O-R- 



-Sb— 
-B/Y- 
-R/B- 
-Gy— 

-L 



-Br- 



Br Br Bj 



-B-7- 



© 



!>®Tl 



® 



@ 



Ik 

a,* 



>/g| -L r/g |— r/w--*— -^- X 

8tjr[Vt.B- L 1 \%h^ 



B/Y 
VB 



¥r 



® 



dqd^L^-jJj 




r " 



,|®n|® 




e r -0-G/R^^-^ 

-— Gy — ^@ 



@ 



® 



© 



® 



r-Br— (o) — P— O O-^ 



M 



® 



Li p^-i ijjji 

,er^@®i^^ 

^Br~^ — VWjOO^ 
L/W -— 14^ © I 



-Sb ' 



I Br Br 



-L/B 



HI 



LO 



oto 



OO 




L L L L 



(0(0(00 



7-5 



ELECTRIC STARTING SYSTEM |ELEC| 



Aforementioned circuit diagram shows electrical starting circuit in wiring diagram. 



NOTE: 

For the encircled numbers and color cords, see page 7-2. 



<2§) 


Relay unit 


£0 


Starting circuit cut-off relay 


<$ 


Starter switch 


@ 


Main fuse 


© 


Battery 


(46) 


Starter motor 


© 


Starter realy 


m 


Main switch 


# 


Fuse (IGNITION) 


^ 


"ENGINE STOP" switch 


a 


Clutch switch 


5$ 


Diode 


<® 


Sidestand switch 


& 


Sidestand relay 




7-6 



ELEC 



ELECTRT STARTING SYSTEM 



TROUBLESHOOTING 
Troubleshooting Chart (1) 






THE STARTER MOTOR DOES NOT 
OPERATE. 



& 



Remove the seat. 



4 



D isconnect the "L/&T " lead from the starter 
relay. 



& 



Check the battery voltage (12V) on the 
"L$r " lead from the starter relay. 



NO 



Correct the battery term inal connection. 



Ql 



12V 



Connect the "LAN" lead from the starter 
relay to the battery negative (-) term inah use 
a jam per lead (0 . 




"> 



^^fc] The engine does not operate. 



5 



I the starter relay does not click; replace the 

relay. 




~\ ! 



The engiie does not rev sm oothly, 



& 



Recharge orreplace the battery. 



n 



7-7 



ELECTRT STARTING SYSTEM 



ELEC 59 



Troubleshooting Chart (2) 



THE STARTER MOTOR DOES NOT OPE- 
RATE. 



& 



Check the Starter reky and starter m otor; 
refer to CHART (1). 



£ 



Remove the cover (left) and disconnect 
the relay unit connector. 



^ 



Main and engine stop switches are turned to 
"ON". 



4> 



... 
Check the battery voltage (12V) on the 
"R/B" lead. 








■ 






u_ 


Br/W 


\xt 


L/W 


L/W 




W/G 


Y/R 


B 


B/Y 


R/B 









NO 



Check for an open or poor connection between 
the m aii sw nto h and relay unit. 



^> 



12V 



Connect the relay unit connector. 



£ 



Connect "B/Y" lead to "ground" on the 

fiame; use a jimper bad (p . 




4 



If the relay unit does not click, replace the 
relay unit. 



IE the relay un± clicks, check the starter, 
cliteh and neutral sw itches . R epfece sw itch 
(es) if necessary. 



ELECTRIC STARTING SYSTEM 



-<r\j> 



© 



& 



© 



n 








^nmtnnJ 
-M — —-? 



i 



*** 



nrrv 



@ 




$• 1/ 



® 



STARTING CIRCUIT CUT-OFF SYSTEM 

A starting circuit cut-off system is employed, 

and operates as follows: 

Starting Circuit Operation 
The starting circuit on this model consist of 
the starter motor, starter relay, and the relay 
unit (starting circuit cut-off relay). If the engine 
stop switch and the main switch are both on, 
the starter motor can operate only if: 



The 


transmission is 


> in neutral (the neutral 


switch is on). 








or if 


The 


clutch lever is 


pulled to the handlebar 


(the 


clutch switch 


is on) and the sidestand 


is up (the sidestand switch is on.) 



The starting circuit cut-off relay prevents the 
starter from operating when neither of these 
conditions has been met. In this instance, the 
starting circuit cut-off relay is off so current 
cannot reach the starter motor. 

When one of both of the above conditons 
have been met, however, the starting circuit 
cut-off relay is on, and the engine can be started 
by pressing the starter switch. 



i 

<D 

© 

5.; 
© 

7 

<D 
® 

10 



WHEN THE TRANSMISSION B IN 

NEURTAL 
^m WHEN THE SIDESTAND IS UP AND 

THE CLUTCH LEVER IS PULLED IN 
4o« WHEN THE ENGINE IS RUNNING 

Battery 

Starter motor 

Starter relay 

Starting circuit cut-off relay 

Starter switch 

Neutral switch 

Sidestand switch 

Clutch switch 

Sidestand relay 

To V-boost valve control unit 

To main switch 

To engine stop switch 

TO ignitor unit 



7-9 



ELECTRIC STARTING SYSTEM 



STARTER MOTOR TEST 

(f) O-ring 

(D Brush holder assembly 

(D Oil seal 

(4) Brush 



^ 



MINIMUM BRUSH LENGTH: 
5.5 mm (0.22 in) 



COMMUTATOR WEAR LIMIT: 
27 mm {1.06 in) 



MICA UNDERCUT: 
0.7mm (0.028 in) 




7-10 



ELEC 



ELECTRIC STARTING SYSTEM 



Removal 

1. Remove: 
•Starter motor 

Refer to "CHAPTER 

ASSEMBLY" section. 



3. ENGINE DIS- 




Inspectionand Repair 

1. Inspect: 
Commutator 

Dirty -> Clean with #600 grit sandpaper. 

2. Measure: 
Commutator diameter (a) 

Out of specification ->• Replace starter 
motor. 




Commutator Wear Limit: 
27 mm (1.06 in) 



3. Measure: 

• Mica undercut (B) 
(between commutator segments) 
Out of specification -*• Scrape mica to 
proper valve. 
Use a hacksaw blade that is ground to fit. 



""> 




Mica Undercut: 
0.7 mm (0.028 in) 



NOTE: 

The mica insulation of the commutator must be 
undercut to ensure proper operation of the 
commutator. 




4. Measure: 

•Armature coil insulation/continuity 
Defect(s) -* Replace starter motor. 



I © 



Insulation Resistance: 

1 Mi2 or more a 1 20°C (68° F) 



(T) Continuity check 

(2) Insulation check 

(3) Armature coil 



7-11 



ELECTRIC STARTING SYSTEM 



ELEC 




5. Inspect: 
•Bearings© 
•Oil seal (D 

•0-ring(3) 
Wear/Damage - 



Replace 



6. Inspect: 
•Commutator brushes 

Damage-* Replace. 

7. Measure: 

• Brush length® 
Out of specification -> Replace. 




Minimum Brush Length: 
5.5 mm (0.22 in) 



8. Inspect: 
• Brush springs 
Compare with new spring. 
Wear/Damage -> Replace. 




Installation 
1. Install: 
•Starter motor 

NOTE: 



Align the match marks © on the brackets with 
the match marks (2) on the housing. 



7-12 



EL^S 



ELECTRIC STARTING SYSTEM 



BATTERY INSPECTION 
1. Inspect: 
• Battery 
Refer to "CHAPTER 
SPECTION" section. 



2 BATTERY IN- 





STARTER RELAYTEST 
1. Inspect: 
•Starter realy 
Poorcondition-> Replace. 
By the following inspection steps. 



Starter relay inspection steps: 

• Remove the seat. 

•Turn ignition switch to "ON", engine stop 
switch to "RUN"and shift pedal to "NEUT- 
RAL". 

• Disconnect the starter motor lead © from 
the starter motor. 

• Push the starter switch and check to see if 
the starter relay clicks. 

Starter relay clicking -> Starter relay OK. 
Starter relay not clicking -*■ Measure coil 
resistance. 



2. Measure: 

•Starter relay resistance 
Out of specification -» Replace. 
By the following measurement steps. 



Starter relay resistance measurement steps: 
.Disconnect the "L/W" lead and the battery 

positive lead. 
•Connect the Pocket Tester (YU-031 12) leads 

to the starter relay. 
(D Blue/White 
(2) Red 
• Measure the coil resistance. 



K. 







Starter Relay Resistance: 
3.5 n ± 10%at20°C (68°F) 



»lf the resistance is not within specification, 
replace the starter relay. 






""> 



7-13 



ELECTRIC STARTING SYSTEM 



ELEC M 




22552 



UW 



of 



R/B 



L/W 



B/Y 



■ Bt- 



^\ 



Br 



Y/R W/G 



¥ 




^f 



CD 




STARTING CIRCUIT CUT-OFF RELAY TEST 

1. Remove: 
•Top cover 
•Cover (left) 

• Relay unit 

2. Disconnect: 

• Relay unit connector 



3. Measure: 

•Starting circuit out-off relay resistance 
Use the Pocket Tester© (YU-031 12). 
Out of specification -► Replace. 



Kl 


Starting Circuit Cut-off Relay Resist- 


-@: 


ance: 


LiA u ± luxfoat zirt; <e» !-j 



(2) Red/Black 
(D Black/Yellow 

4. Check: 

•Starting circuit cut-off relay contacts 
Use 12V battery © and the Pocket Tester 
(I) (YU-031 12). 
Out of specification^- Replace. 



Battery Connected (3) :0ft 
Batterv Disconnected (A) : oo 



© Blue/Withe 
(6) Red/Black 
(?) Black/Yellow 




SIDESTAND RELAY TEST 

1. Remove: 
•Top cover 
•Cover (left) 

• Electrical components board 
•Sidestand relay © 



7-14 



WH 



ELECTRT STARTING SYSTEM 




2. Check: 

•Sidestand relay contacts 

Use 12V battery (T)| and the PocketTester 

dH (YU-03112). 

utof specification •* R epkce relay. 



FT 



o 



Battery Connected ® : oo 
Battery Disconnected ® : 



on 



(5^| Blae/SreUow 

(|£| Red/White 

(J) Blacker hie 

(f) Black 










DDDE TEST 
1 . R em ove : 
•Top| cover 

• Meter panel 
*Dbde O 

2. Check: 

• Diode continuity /discontinuity 
Defective etem ent(s) -* Replace diode. 



Checking 

element 


Pocket tester 
connecting point 


Good 


(+} 

(Red) 


(-) 

(Black) 


D, 


G 


L/W 


o 


L/W 


G 


X 


D 2 


Y 


Sb 


o 


Sb 


Y 


X 


D 3 


W/G 


W 


o 


W 


W/G 


X 


R 


G 


B/R 


8.20 


O J Conliiuly (Oij j| ^ud-tj—ia ^ j. <\,| — 
X : Discontinuity (»)| (Scale flj x 1 J 

NOTE : 


The results "0" or "X" should be 
according to the Pocket Tester polarity 


reversed 



^ 



"> 



""> 



7-15 



r> 



r> 



ELECTRIC STARTING SYSTEM 




NEUTRAL SWITCH TEST 

1. Disconnect: 
•One lead (Blue) 

2. Check: 

• Neutral switch contact 
Out of specification -> Replace switch. 



£ 



In Neutral © 
In Gear © 



on 



oo 



J 



(3) Blue 
© Ground 



/"^ 




SIDESTAND SWITCH TEST 

1. Remove: 

•Side cover (left) 

2. Disconnect: 

02-pin connector (Blue/Yellow and Black) 

3. Check: 

•Sidestand switch contacts 
Out of specification -► Replace switch. 






Sidestand Up © : OO 
Sidestand Down © : oo 



(3) Blue/Yellow 

(4) Black 



7-16 



CHARGING SYSTEM 



CHARGING SYSTEM 

CIRCUIT DIAGRAM 




7-17 



CHARGING SYSTEM 



Afcrementioned circuit diagram shows charging circuit in wiring diagram. 



NOTE: 

For the encircled numbers and color codes, see page 7-2. 



© AC Magneto 

@ Rectifier with regulator 

(§) Main fuse 

© Battery 

(£3) Main switch 




7-18 



CHARGING SYSTEM 



TROUBLESHOOTING 



THE BATTERY IS NOT CHARGED. 



^ 



Remove the seat. 



^ 



Zl 



Measure the battery for voltage and specific 

gravity. 

B attery volage : M oie than 12V 
Specific gravity: 1,280 



No. 



■frl Recharge me battery. 



& 



Yes 



Connect the Pocket Tester to the battery 

to measuiE the generator volage. 




Start the engine and accelerate to about 
2,000 r/min or more. 



& 



Generator Voltage: 

More than 1 5V 



Generator Voltage: 

Less than 13V 



£ 



4> 



Replace rectifier with regulator. 



Check the starter coil resistance. 
Stator coil resistance (White-White): 
0.42 n ± 15%at20 D C{68°F) 



£ 



Replace the starter coil. 



"^ 



-^ 



7 19 



CHARGING SYSTEM 




CHARGING VOLTAGE TEST 

1. Remove: 
*Seat 

2. Connect: 

• Pocket Tester (YU-031 12) 
To battery terminals. 

3. Start the engine and accelerate to about 
2,000 r/min or more. 

4. Measure: 
•Generator voltage 

Out of specification ■+ Check battery, 
stator coil, and rectifier/regulator. 



E3 



Generator Voltage: 14.5 ± 0.5V 



CAUTION; 



Never disconnect the wires from the battery 
while the generator is operating, otherwise the 
voltage across the generator terminals will 
increase and damage the semiconductors. 



BATTERY INSPECTION 

Refer to "CHAPTER 2 BATTERY INSPEC- 

TIOlSTsection. 



STATOR COIL RESISTANCE TEST 
1. Remove: 

*Side cover (left) 
2 Disconnect: 

03-pin conn'ector (White, White and White) 
From rectifier/regulator. 
3. Connect: 

• Pocket Tester (YU-031 12) 



7-20 



CHARGING SYSTEM 




& 



CD 



or 



— V- 



© 

4- 



E 



Dl 



D4 



DiTDj 



t 



TJitK" 



-K» — 



® 



la! 



4. Measure: 

•Statorcoil resistance 
Out of specification -* Replace stator coils. 



5@S 


Stator Coil Resistance: 

0.42H± 15%of20°C(68°F) 




(White — White) 



(T) White 

RECTIFIER TEST 

1. Check: 
• Defective element 

(T) White 

(5) White 

(3) White 

(?) Red 

© Black 



Replace rectifier. 

[A] IC Regulator 
[IF Brown 
fj Rectifier 



Checking 
Element 


Pocket Tester 
Connecting Point 


Good 


Replace 
(Element 
shorted) 


Replace 

(Element 

opened) 




(+) 
(Red) 


(-) 
(Black) 




D, 


d 


a 


O 


O 


X 




3 


d 


X 


O 


X 




D 2 


d 


b 


o 


o 


X 




b 


d 


X 


o 


X 




D 3 


d 


c 


o 


o 


X 




c 


d 


X 


o 


X 




D, 


a 


e 


o 


o 


X 




e 


a 


X 


o 


X 




Ds 


b 


e 


o 


o 


X 




e 


b. 


X 


o 


X 




D 6 


c 


e 


o 


o 


X 




e 


c 


X 


o 


X 





O: Continuity X : Discontinuity (<») 



NOTE: 

The results "O" or "X" should be reversed ac- 
cording to the Pocket Tester polarity. 



i, 



CAUTION: 



Do not overcharge rectifier or damage may result. 
Avoid: 

• A short circuit. 

• Inverting + and — battery leads. 

• Direct connection of rectifier to battery. 



7-21 



— MEMO— 



7-22 



IGNITION SYSTEM 



IGNITION SYSTEM 

CIRCUIT DIAGRAM 



•B/W- 



■R/W- 



<® I B/Y 1 




@ 



O Gy W/R W Z G 

trtrtj 



Y 'R Br/W 





B/Y 

R - eL RT 



si 



iV-V--^ 1 



i 



L/W 



Y 



OO 



OO 



—LAV fd«-J J| 

«h 1 



——l 

Br Br 



L/W 



1 



r" 



iBr" 



01 01 r— 



Br 



,® 



R/Y 



-^ 



t-l/B- 



OO 



* "= 




7 



> ) @£)© 




^ 



~> 



~> 



7-23 



IGNITION SYSTEM 



Aforementioned circuit diagram shows ignition circuit in wiring diagram. 



NOTE: 



For the encircled numbers and color codes, see page7-2. 



(D 


Ignition coil #1 


m 


Main switch 


(2) 


Spark plug #1 


A 


Fuse (IGNITION) 


(3) 


Ignition coil #2 


K 


"ENGINE STOP" swit 


(4) 


Spark plug #2 


®> 


Sidestand relay 


(5) 


ignition coil #3 


A 


Pressure sensor 


(§) 


Spark plug #3 


® 


ignitor unit 


(Z) 


Ignition coil #4 


@> 


Pick-up coil (#1~#4) 


(8) 


Spark plug #4 








7-24 



ELEC S= 



IGNITION SYSTEM 



TROUBLESHOOTING 

The entire ignition system can be checked for 
misfire and weak spark by using the Electro 
Tester. 
1. Warm up the engine so that all of the electri- 
cal components are at operating temperature. 




2. Connect: 

• Electro Tester (YU-33260) (D 

3. Start the engine, and increase the spark gap 
until misfire occurs. (Test at various r/min 
between idle and red line.) 



(2) Spark plug lead 

(3) Spark plug 



CAUTION: 



Do not run the engine in neutral above 6,000 
r/min for more than 1 or 2 seconds. 




Minimum Spark Gap: 6 mm (0.24 in) 



Faulty ignition system operation (at the mini- 
mum spark gap or smaller)* Follow the trouble- 
shooting chart until the source of the problem 
is located. 



^ 



7-25 



IGNITION SYSTEM 



ELEC 



Troubleshooting Chart 



Check the entire ignition for connections. 



Correct. 



O 



Measure the battery voltage and .specific 

gravity. 

Battery voltage: More than 12V 

Specific gravity: 1,280 No 



-► 

Faulty 

■vl Recharge the battery. 



O 



Main and engine stop switches are turned to 
"ON". Check for voltage ( 1 2V) on the "R/W" 
lead at the TCI unit and ignition coils. 

TT 



o 



4 



No 



Check the fuse "IGNITION" (15A) 
and wiring circuit. 



Measure the pickup coils resistance. 
Pickupcoil: 110n + 1 5% a t 20°C (68"F) 
(Orange — Black) (Orange — Gray) 
(Orange — White/Green) 
(Orange -White/Red) 




M Replacethe pickupcoil assembly. 
No 



O OK 



Check the ignition coils for resistance (primary and secondary). 



Primarv: 2.7ft ± 10% at 20°C (68° F) 



o_ 




Secondary: 13.2 kft ± 20%at20°C (68°F) 
13.2 Kfi 



V s 


J2x100 ° 
9- + ? 




No 



TCI unit isfaulty, replacethe unit. 



Replacethe ignition coil(s). 



7-26 



IGNITION SYSTEM 





DESCRIPTION 

This model is equipped with a battery operated, 
fully transistorized, breakerless ignition system. 
By using magnetic pickup coils, the need for 
contact breaker points is eliminated. This adds 
to the dependability of the system by eliminating 

frequent cleaning and adjustment of points 
and ignition timing. The TCI (TransistorControl 

Ignition) unit incorporates an automatic ad- 
vance circuit controlled by signals generated by 
the pickup coil. This adds to the dependability 
of the system by eliminating the mechanical 
advancer. This TCI system consists of two units; 
a pickup unit and an ignitor unit. 



\K Pressure sensor 

| | Pickup coil 

| | Ignitor unit 

I | Advance control 

| | Electronic advance circuit 

ff] Ignition coil x 4 

I I Spark plug x 4 

□ Battery 

OPERATION 

TCI Unit 

The TCI functions on the same principle as a 
conventional DC ignition system with the 
exception of using magnetic pickup coils and a 
transistor control box (TCI) in place of contact 
breaker points. 

(T) TCI unit 

Pickup Unit 

The pickup unit consists of two pickup coils (T) 
and a flywheel mounted onto the crankshaft. 
When the projection on the flywheel passes a 
pickup coil, a signal i s generated and transmitted 
to the ignitor unit. The width of the projection 
on the flywheel determines the ignition advance. 
The pickup coils are located in the right crank- 
case cover. 



7-27 



IGNITION SYSTEM 








-_^J 



13.2 ki2 






IGNITION SPARK GAP TEST 

1. Remove: 
•Top cover 
•Seat 

• Cover (left) 

• Electrical component board 

2. Disconnect: 

• Ignition coil leads 
•Spark plug leads 

3. Connect: 

• Electro Tester (YU-33260) 



NOTE: 

Be sure to use a fully charge 12V battery® . 

4. Turn the spark plug gap adjuster and increase 
the gap to the maximum limit unless misfire 
occurs first. 




Minimum Spark Gap: 6 mm (0.24 in) 



IGNITION COIL RESISTANCE TEST 

1. Connect: 

• Pocket Tester (YU-031 12) 

2. Measure: 

•Primary coil resistance E 
•Secondary coil resistance E 
Out of specification -> Replace. 



Primary Coil Resistance: 
2.7ft ± 10%at20°C(68"F) 

Secondary Coil Resistance: 
13.2kft ±20%at20°C{68°F) 

Spark Plug Cap: 
10kft ± 10% 



7-28 



IGNITION SYSTEM 




PICKUP COIL RESISTANCE TEST 

1. Remove: 
•Seat 

2. Disconnect: 

•5-pin connecter (Black, White/Red, Orange, 
White/Green and Gray) 

3. Measure 

• Pickup coil resistance 

Use a PocketTester(YU-03112). 
Out of specification -> Replace. 



K 



Pickup Coil Resistance: 
11(K2± 10%at20°C(68°F) 
{0-B),(0-Gy),<0-W/G), 
(O -W/R) 



(D Black 
© White/Red 
(f) Orange 
(4) Gray 
(J) White/Green 

SPARK PLUG INSPECTION 

Refer to "CHAPTER 2 SPARK PLUG IN- 
SPECTION- section. 




PRESSURE SENSOR 
Operation 

This pressure sensor unit consists of a semi- 
conductor strain gauge and an amplifying circuit. 
Pressure to the carburetorjoint (venturi portion) 
is sensed by the strain gauge and amplified in 
the circuit connected with this gauge. The 
amplified pressure signals are then transmitted 
to the ignition system for the control of ignition 
timing advance. 



(T) Strain gauge 

(2) Amplifying circuit 

(3) Pressure intake tube 

(4) From carburetor joint 



7-29 



IGNITION SYSTEM 



ELEC 






600 fa Ofa SOOmmHg 



Removal 

1. Remove: 
•Top cover 
•Cover (left) 

• Electrical component board 

2. Disconnect: 
•Sensor connector 
•Vacuum hose 

3. Remove: 
•Pressure sensor ® 

Inspection 

1. Connect: 

•Pocket Tester ( YU-031 1 2) 
•Battery (12V) (D 

2. Measure: 
•Output voltage 

Out of specification -» Replace. 



Ijf5 



Output Voltage: About 2.0 DC Volt 



(T) Output voltage 

(g) Atmospheric pressure 

(f) Pressure 

Installation 
1. Install: 
•Pressure sensor 
Reverse the removal procedure. 



7-30 



LIGHTING SYSTEM 



LIGHTING SYSTEM 
CIRCUIT DIAGRAM 




7-31 



LIGHTING SYSTEM 



Aforementioned circuit diagram shows lighting circuit in wiring diagram. 



NOTE: 

For the encircled numbers and color codes, see page 7-2. 



@ "LIGHTS" (Dimmer) switch 

© Headlight 

@ "HIGH BEAM" indicator light 

@ Meter lights 

§ Tail/brake light 
Fuse (HEAD) 

(£§) Starter switch 

@ Main fuse 

® Battery 

<£$) Main switch 




7-32 



=ss 



LIGHTING SYSTEM 



LIGHTING TESTS AND CHECKS 

The battery provides power for operation of 

the headlight, taillight, and meter lights. If 

none of the above fail to operate proceed further. 

Low battery voltage indicates either a faulty 

battery, low battery fluid level, or a defective 

charging system. 

Also check fuse condition. Replace any "open" 

fuses. There are individual fuses for various 

circuits (see complete Circuit Diagram). 

NOTE: 

Check each bulb first before performing the 
following check. 



7-33 



LEHTUG SYSTEM 



ELEC 



Headlight Troubleshooting 



^ 



HEADLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING/HIGH BEAM DOES NOT 
OPERATION. 



~& 



Check headlight bulb. 



Faulty 



Replace . 



^ 



OK 



Faulty 



Check fuse (HEAD). 



n*o 



Rephce. 



^JrOK 



^ 



Measure voltage on Brown lead from 
main switch ("ON" position). 



$> 



Faulty 



4E 



Check man switch, replace if necessary. 



12V 



Measure voltage on Blue/Black lead from 
"START" switch ("ON" posiliun). 



4> 



12V 



Measure voltage at "LIGHTS" (Dimmer) 
switch terminal. 



No voltage 

By | Check 'START" switch, if necessary, j 

No voltage 



Check "LIGHTS" (Dimmer) switch, re- 
place if necessary. 



& 



12V 



No voltage 



Measure voltage at headlight high beam 
or low beam terminal. 



4 



4> 



12V 



An open or poor connection between 
headlight and "LIGHTS" (Dimmer) switch 
terminal. 



Poor ground or poor connection of head- 
light w img . 



7-34 



ELEC 


u 


. LIGHTING SYSTEM 


*■ 



Taillight Troubleshooting 



TAILLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING. 



^ 



Check taillight bulb. 



& 



Faulty 
JHpl Replace. 



OK 



Check main fuse. 



^ 



Faulty 

JHfc Replace. 



OK 



Measure voltage on Blue lead from main 
switch ("ON" position). 



Novoltaae 



Check main switch, replace if necessary. 



4V 



12v 



No voltage 



Measure voltage at taillight terminal, 



An open or poor connection betweentailligh 
and main switch terminal. 



Poor ground or poor connection of taillight 
wiring. 



7-35 



— MEMO — 



7-36 



ELEC 



SIGNAL SYSTEM 



SIGNAL SYSTEM 
CIRCUIT DIAGRAM 




"^ 



^ 



"> 



7-37 



SIGNAL SYSTEM 



ELEC 



Aforementioned circuit diagram shows signal circuit in wiring diagram. 
NOTE: 



For the encircled numbers and color codes, see page 7-2. 



@ Horn 




@ Flasher relay 


@ "HORN "switch 




@ Canelling unit 


<0j) "OIL LEVEL" warning 


indicator light 


@ "TURN" switch 


@ Oil level gauge 




@ "TURN" indicator light 


(f$) "NEUTRAL" indicator 


light 


@ Parking/Running light 


@ Neutral switch 




@ Flasher light 


@ Front brake switch 




@) Reedswitch 


@ Rear brake switch 




@ Main fuse 


@ Tail/brake light 




@ Battery 


® Fuse (SIGNAL) 




@ Main switch 


@ Relay assembly 








7-38 



SIGNAL SYSTEM 



SIGNAL SYSTEM TESTS AND CHECKS 

The battery provides powerfor operation of the 
horn, brakelight, indicator lights and flasher 
lights. If none of the above operates, always 
check battery voltage before proceedingfurther. 



Battery 

1. Check: 
• Battery voltage 



Defective components -► Replace. 


Check for: 


Faulty battery 


Low battery fluid level 


Defective charninn system 


Faulty fuse(s) 



Horn 

1. Check: 
• Horn operation 
Defective components - 



Replace. 



Check for: 



12V on Brown lead to horn 



Good grounding of horn (Pink 
lead) when horn button is pressed 



Faulty fuse 



Brake Light 

1. Check: 
• Brake light operation 
Defective components - 



Replace. 



Check for: 



Defective bulb 



12V on Yellow lead to brake light 



12V on Brown lead to each brake 
light switch (Frontand rear brake 
switch) 



•NEUTRAL" Indicator Light 

1. Check: 
• Indicator light operation 
Defective components-*- Replace. 



Check for: 



Defective bulb 



12V on Sky Blue lead to neutral 
switch 



12V on Brown lead to indicator 

light 



7-39 



SIGNAL SYSTEM 



■D1L LEVEL" Warning Indicator Light 
1. Check: 
• Indicator light operation 
Defective components -> Replace. 



Check for: 



I 



Defective bulb 



Defective oil level gauge 



12V on Brown lead to indicator 
light I 



Flasher Light 
1. Check: 
• Flasher I ight operation 
Refer to "SELF-CANCELLING FLASHER 
SYSTEM" section. 




OIL LEVELGAUGETEST 

1. Drain: 

• Engine oil 

2. Remove: 

•Oil level gauge 

3. Measure: 

•Oil level gauge resistance 
Use the Pocket Tester (YU-031 12). 
Out of specification ->• Replace. 



K3 



Oil Level Gauge Resistance: 
Float is down (a) -> Infinity 
Float is up(B) -*■ Zero ohms 



® Black/Red 
(f) Ground 

4. Install: 

•Oil level gauge 

5. Connect: 
• Leads 

6. Fill: 
Crankcase 

Refer to "CHAPTER 2 ENGINE OIL RE- 
PLACEMENT" section. 



7-40 




SIGNAL §Y§TfM 




REED SWITCH TEST 

1. Remove: 
*Headlight lens unit ■ 
•Top cover 

• Cover (left) 

2. Disconnect: 

*Relay assembly coupler © 

3. Measure: 

• Reed switch resistance 

Use the Pocket Tester {YU-031 12). 
Out of specification -> Replace. 
Lift the front wheel and rotate the wheel 
by hand. 



ID 



Reed Switch Resistance: 

Ahmit 7n 

Then return back On oroon 
when wheel is stopped 

imiji' ''ju-ju i ^> : « lw jl* ||U i^U 



© White/Green 
(2) Black 



SELF-CANCELLING 
TEST 



FLASHER SYSTEM 




Description 

The self-cancelling flasher system turns off the 

turn signal after a period of time or distance 
involved in turning or changing lanes. Generally, 
the signal will cancel after either 10 seconds, 
or 150 meters (490 feet), whichever is greater. 
At very low speed, the function is determined 
by distance; at high speed, especially when 
changing speeds the cancelling determination is a 
combination of both times and distance. The 
self-concelling determination is a commechanism 
only operates when the motorcycle is moving; 
thus the signal will not self-cancel while you are 
stopped at an intersection. 



(T) Cancelling unit 



7-41 



SIGNAL SYSTEM 



ELECl 



Operation 

The handlebar switch has three positions: 

L (left), OFF, and R (right). The switch lever 

will return to the "OFF" position after being 

pushed to L or R, but the signal will function. 

By pushing the lever in, the signal may be 

cancelled manually. If the flasher self-cancelling 

system should become inoperative, replace relay 

unit. 



Troubleshooting 



Flasher light and indicator light inoperative. 



^ 



Check bulb. 



Faulty 



Replace. 





OK 


& 




Left circuit 








• Check for 


12V on 


Chocolate lead t 


d light. 


Check for 


ground 


on Black lead to 


light. 


Right circu 


t: 






• Check for 


12V on 


Dark green lead 


to light. 


Checkfor 


ground 


on Black lead to 


light. 



No voltage 



Correct. 



OK 



£ 



Measure voltage at "TURN "switch as follows. 

• Brown/White lead 

• Yellow/Red lead 



111/ 

I £. V 



Replace switch. 



No 



voltage J^L 



No voltage on Brown/White lead: 

• Check flasher relay, fuses (SIGNAL and 
MAIN), main switch and battery. 

No voltage on Yellow/Red lead: 

• Check cancelling unit, fuses (SIGNAL and 
MAIN), main switch and battery. 



Poor condition 



Replace defective component(s) 



OK 



4> 



Poor condition 



Check reed switch. 



Replace switch. 



OK 



<0> 



Replace cancelling unit. 



7-42 



ELEC 



SIGNAL SYSTEM 




SWITCHES TEST 

Switches may be checked for continuity with a 

Pocket Tester {YU-03112) on the "Ohm x 1" 

position. 

(T; "LIGHTS" (Dimmer) switch 

(f) "TURN" switch 

(3) "HORN" switch 

© "ENGINE STOP" switch 

(D "START" switch 



Main Switch 



1 

Switch Position 


Lead Color 




R 


Br 


L 


P 


r\ 




(™i 


U 




\j 


OFF 








ON 


o 


O 


O 



"LIGHTS" (Dimmer) Switch 



Switch Position 



Lead Color 



HI 



O- 



-O 



LO 



o- 



-o 



"TURN" Switch 



1 




Lead Color 


oWltcn rOsiiiun 


Ch 


Br/W 


Dg 


Y/R 


B 


L 


r\ 






o 


n 


U 




LJ 




N 


L 


O 


r\ 








U 






N 












R 




n 


. o 












R 


- 


r^ 






(— i 


n 




VJ 


\j 




r vj 



"HORN" Switch 



Switch Position 


Lead Color 






OFF 






ON 






u 


u 



-^ 



~> 



7-43 



SIGNAL SYSTEM 



ELEC 



Switch Position 


Lead Color 


R/W 


RIB 


OFF 






ON 


o 


jO 


\j 





■START" Switch 



Switch Position 



Color Code 
Co l o riCode 

' /W 



R/Y | L/B | L 



:ol 



OFF 

ON 



O- 



-o 



o- 



7-44 



COOLING SYSTEM 



COOLING SYSTEM 
CIRCUIT DIAGRAM 



I 1 



-r- 

R/W 
I 



© 



© 



R/B <§> 

i—O o— +-U 



1 f- 

R/W R/W 



R/W Gy 

6 |© 




ON 



OFF 



Br 



ooo 



Br 



B/Y 



L/Y 



® 



B/Y Sb L/Y 



■B/W- 



© 



fl/W-*-R/W- 

-B/R- 
-B/Y— 



|© 



I — Gy- 



r 



t — r 

B B 



i — w- 



R/W 



B 

1 



O Gy W/R W Z G 

Lrirtro 



J. R/G i—! 

"=■_! L 

l/b] @ _ B 



R/W- 



© 




-Sb— 
-8/Y- 
-R/B- 



-Gy- 

-L- 



-Br- 



Br Br B, 



q 



\ - 



G Br 






B/Y 
R/B 









Y/R Br /w 



Ch /p9 

W 



Ch Ch 





^Br— (O) — P— O O— ^ 
G ^n © 



(D ©H 

Br— fVVG/R ^WV^ -i 



-Gy- 



Bf 



,® 



© 



@ B/R JL " 



— L/W --H-l © " 

Br-^^Sb^O C^_ 

Ck 



r— L/B 




L/B * « 



Irn 

® 






^ 



7-45 



COOLING SYSTEM 



H 



Aforementioned circuit diagram shows cooling circuit in wiring diagram. 



NOTE: 

For the encircled numbers and color codes, see page 7-2. 



(9) Temperature meter 

(f§) Thermo-unit 

@ Fuse (SIGNAL) 

@ Thermostatic switch 

■© Electric fan 

© Fuse 

@ Main fuse 

@ Battery 

@ Main switch 




7-46 



COOLING SYSTEM 



TROUBLESHOOTING 



The electric fan will not turn at coolant temperatures of 105 ± 3°C (221.0 ± 37.4" F) or more: 



& 



Defective 



Check the connectors. 



Correct. 



& 



OK 



Disconnect fan motor connector and 
connect battery as shown. 




(f) Electric 

fan 
© Black 
CD Blue 
® Battery 



Fan inoperative 



■w 



Replace fan motor assembly. 



Check battery voltage on Blue leads 



I I Fan operative Novoltage 



& 



12V 



Check wiring circuit, and correct defective 
component(s) . 



Disconnect the lead of the thermostatic 
switch and ground it to the motor body. 



Fan operative 



<■[ 



Replacethe thermostatic switch. 



* 



Fan inoperative 



Replacethe fan motor ass.embly. 



7-47 



COOLUG SYSTEM 




J 1 



lJ 



98°d 
<208.4°F) 



105±3°d 
t22i ,0±l5.4 o F| 



:e| 




ELECTRE 
SW ITCH 



FAN AND THERMO STATE 



Opera tbn 

The electric fen wiD.be switched ON or O FF 

accoidiig to the coolant tern peratuie ii the 

radiator. 



''■I 



E lectdc fen 



NOTE : 

The electric fen is controlled by the theim osteite 
switch when the mail switch is 'ON". Thus, 
under certain opera thg conditions, this fen m ay 
continue to run until the engine tern peratuie 
has cooled down to about 91 °C (195.8" F)J 



[A| thermostate switch "ON" 

(JO COOLANT TEMPERATURE 

Electric Fan Inspection 



The fclbw iig problem s m ay lequire lepairor 
replacement of components 


Component 


Condition 


Fan motor 


Unsmooth operation 


Fan motor 


Excessive vibration 


Fan motor bracket 


Cracks 


Fan blades 


Cracks 


Securing bolts 


Looseness 



*~ 



Fan 

(2}j E lectdc fen m otor 




Therm ostatic Sw itch Iispectbn 
1 . R em ove : 
*Top cover 
*Cover (right) 
*Theim osteite sw itch Qj 



WARNING: 



Handle the thermostatic valve very carefully. 
Never subject it to strong shock or allow it to 
be dropped. Should it be dropped, it m ust be 
replaced . 



7^8 



COOLING SYSTEM 




2. Inspect: 

•Thermostatic switch operation 
By the following inspection steps. 



Thermostatic switch inspection steps: 

• Immerse thermostatic switch in water. 

(J) Thermometer 

(2) Thermostatic switch 

(3) Pocket Tester 

• Check continuity as indicated. 

Note temperatures while heating the water. 
Malfunction -> Replace switch. 


Test 
Step 


Water Temperature 


Pocket Tester 
(£2x1] 


1 


- 98°C 
(32- 208.4° F) 


Discontinuity 


2 


More than 105+ 3°C 
(221.05 5.4° F) 


Continuity 


3" 


105to98°C 
(221 to 208.4" F) 


Continuity 


4* 


Less than 98°C 

(208 4" F) Discontinuity 


Test 1 &2; Heat-up tests 
Test 3" & 4"; Cool-down tests 



3. Install: 
•Thermostatic switch 



ffl 



Thermostatic Switch: 

15Nm(1.5nvkg, 11ft-lb) 
Three Bond Sealock® #10 



CAUTION: 



After replacing the therrnostaic switch, check 
the coolant level in the radiator and also check 
for any leakage. 






^ 




7-49 



THERMO-UNITAND THERMOMETER 

Operation 

The thermo unit has less resistance at higher 
temperatures and thus allows more current to 
pass through. When more current flows to the 
coil in the thermometer, the armature to which 
the needle is attached by the increased magnetic 
field. In this way, the needle indicates the tem- 
perature. 

(T) Temperature meter 

(2) Red zone 



COOLING SYSTEM 



Therm o-unit. Inspection 
1. Remove: 

• Top cover 

• Cover (right) 
•Thermo-unit® 



WARNING: 




A h M *> t 



Handle the thermo-unit with special care. Never 
subject it to strong shock or allow it to be drop- 
ped. Should it be dropped, it must be replaced. 

2. Inspect: 

•Thermo-unit operation 
By the following inspection steps. 



Thermo-unit inspection steps: 
• Immerse thermo-unit in water. 

(T) Temperature gauge 

(2) Thermo-unit 

(3) Pocket Tester 
(?) Water 

Check continuity at indicated 
Note temperatuers while heating the water. 
Malfunction -» Replace switch. 



Water 
Temperature 



50°C 
(122"F) 



Resistance 



153.9ft 



80°C 
(176"F) 



47.5- 
56.8ft 



100°C 
(212"F) 



26.2- 
29.3ft 



3. Install: 
•Thermo-unit 




Thermo-unit: 

15Nm(1.5m-kg, 11 ft-1b) 
Three Bond Sealock® #10 



CAUTION; 

After replacing the thermo-unit, check the 
coolant level in the radiator and also check for 
any leakage. 



7-50 



ELEC 



FUEL PUMP SYSTEM 



FUEL PUMP SYSTEM 

CIRCUIT DIAGRAM 






■■i 



H/U <$& 



r © 




m 



OFF 



ooo 



rTa) 



1/W R/V 



B/Y L/Y 

i 

B 



© 



-R7W- 



-B/W- 



■R/W- 



B/Y Sb L/Y 



A 
? 
I 



® 



-B/R- 
-B/Y- 



@ 



3 



— Gy- 
-Y- 



B B 



-w- 



r 



R/W 



| -L.R/G 

Lrtrtr 



| l— 1 -Br 

I — fit — I© 







r— Br— J 



^ 



® 
-R— CN^O-R- 



-Sb- 
-8/Y- 
-R/B- 
-Gy- 

-L — 



-Br- 



8r Br 



-Bt- 



■gQp 




Lg | ^ ■ 
@® G Br 

l 




B/Y 
R/B 



c4Tj 



Y{R Br/W 




8r-^vVG/R- ^^^ -i 



nL 



Br— (o) — P— O O-^ 

■G- ^-i (ft 



t ® 



® 



Br— ( ^) - 1 C^ ^ l 



-Br-M7^ Sb T° °^- 

Sb ' 



7-51 



FUEL PUMP SYSTEM 



Aforementioned circuit diagram shows fuel pump circuit in wiring diagram. 

NOTE: 

For the encircled numbers and color codes, see page 7-2. 



<f$ "FUEL" indicator light 

(Q) Fuel sender unit 

@ Main fuse 

@ Battery 

@) Main switch 

@ Fuse (IGNITION) 

<|$l "ENGINE STOP" switch 

@) "FUEL"(RESERVE)switch 

© Fuel pump relay 

@ Fuel pump 




7-52 



I l -H 1- 1 



FUEL PUMP SYSTEM 



FUEL PUMPCIRCUIT OPERATION 

The fuel pump circuit consists of the fuel pump 
relay, fuel pump, and fuel reserve switch. 
The fuel pump starts and stops as indicated in 
the chart below. 



® 

® 



Fuel pump relay 

Fuel pump 

Fuel reserve switch in "RES' position 

Fuel reserve switch in "ON" position 

Ignitor unit 

"FUEL" indicator light 

Fuel sender in "FULL" position 

Fuel sender in "EMPTY" position 

Engine stop switch 

Main switch 

To main fuse and battery 










FUEL PUMP 



START 



• Main/Engine stop 
switch turned to 
"ON" 

• Fuel reserve switch 
turned to "RES" 



• Engine turned on 



STOP 



• Fuel warning 
indicator light 
comes on 



• Engine turned off 



~> 



For about 5 seconds 
when carburetorfuel 
level is low 



After about 
0.1 second 



After about 
30 seconds 



After about 
5 seconds 



7-53 



FUEL PUMP SYSTEM 



TROUBLESHOOTING 
TroubleshootingChart (1) 



Fuel pump fails to operate after engine is 
started. 



& 



Start the engine and the fuel pump input 
voltage (Blue/Black lead). 



More than 11V 



& 



Less than 11V 



Check ignitor unit output voltage condition 
(Orange lead) by testing No. 1 (rear) 
cylinder minimum spark gap. (Refer to 
Ignition System Troubleshooting) 



■VJ Check fuel pump, replace if necessary. 

K 

|-j> Check fuel pump relay ground lead. 

,JLok X 



NO 



i 



NO 



Check fuel pump relay, 
replace if necessary. 



Correct. 



Measure ignitor unit input voltage 
(Red/White lead). 

No voltage 






Replace ignitor unit. 



Check engine stop/main switch, main 
fuse and battery. 



1 



^^k Faulty and/or discharge 



Replace faulty parts and/or charge battery. 



7-54 



ELEC M 



FUEL PUMP SYSTEM 



Troubleshooting chart (2) 



Fuel pump fails to operate for a 5 second interval when carburetor fuel level is low with the main/ 
engine stop switches turned to "ON" and fuel reserve switch turned to "RES". 



4 



More than 1 1 V 



*[ 



Stop the engine and turn on the main/ 

engine stop switches and measure the fuel More than 11V 

pump inputvoltage (Blue/Black lead). f~~^ 



Check fuel pump, replace if necessary. 



More than 1 1 V 



Less than 11V 



Turn the fuel reserve switch to "RES" 
and measure the fuel pump input voltage 
(Blue/Black lead). 



Less than 



\> 



MVQ, 



Measure pump relay 
input voltaqe 

(Red/White lead.). 



No voltage 



Check main/engine 
stop switches, main 
fuse, and battery. 



12\, 



No voltage (Measure fuel pump 
relay inputvoltage 
(Red/Green lead). 



No voltage 



* 



Check reserve switch, 
replace if necessary. 



12V 



V 



Check fuel pump relay ground lead. 



OK 



Replace fuel pump relay. 



J_LNn 



Correct ground lead. 



7-55 



FUEL PUMP SYSTEM 



Troubleshooting Chart (3) 



Fuel pump does not stop after 30 seconds when fuel indicater light comes on while engine is running. 



* 



Start the engine and measure the fuel 
pump input voltage 30 seconds after fuel 
sender Green lead is grounded (Blue/ 
Black lead). 



Check fuel pump connections correct if 
necessary. 



Check fuel sender unit resistance. 
Fuel sender unit resistance: 
0.9+ 0.2 Kfl at20°C{68°F) 



& 



OK 



Check fuel pump relay ground lead. 



^> 



OK 



Replace fuel pump relay. 



No 
No 

m 



Replace. 



Correct ground lead. 



7-56 



FUEL PUMP SYSTEM 





"FUEL" (RESERVE) SWITCH TEST 

Switch (T) may be checked for continuity with a 
Pocket Tester (YU-03112) on the "Ohm x 1" 
position. 



Switch Position 



OFF 



ON 



Lead Color 



R/W 



o- 



R/G 







FUEL PUMP RELAY TEST 



1 



Remove: 
•Top cover 

• Cover (left) 

2. Check: 

• Fuel pump operation 

Referto "FUEL PUMP TEST" section. 

3. Measure: 

• Battery voltage 

Use the Pocket Tester (YU-031 12). 
Out of specification-* Replace relay. 
Main and engine stop switches are "ON" po- 
sition. 



E 



Fuel Pump Relay Input Voltage: 
12v 



® Red/White 
(2) Black 

FUELPUMPTEST 

Operation 

The diaphragm is pulled left by the plunger 

allowing fuel to be sucked into the fuel chamber. 

Fuel is pushed out from the pump until carb 

float chamber is filled with fuel, and then the 

cut-off switch cuts off the circuit. 

When the spring pushes the diaphragm further 

to the end, the cut-off switch turns on and the 

solenoid coil pullsthe plungerwith the diaphragm 

forcing fuel into the fuel chamber. 



NOTE: 

When the main and engine stop switches are ON, 
the fuel pump relay is activated for five (5) 
seconds at which time the fuel pump operates. 



7-57 



FUEL PUMP SYSTEM 



ELEC 




(J) Cut-out switch 
(I) Spring 
(D Diaphragm 

(4) Plunger 

(5) Solenoid coil 
(D Fuel chamber 
(7) Valve 

(D Outlet 
(§) Inlet 

Inspection 

1. Connect: 
•Battery (12V) 

2. Check: 

• Fuel pump operation 
Faulty operation -*■ Replace. 

3. Inspect: 

• Fuel pump 
Cracks/Damage ->• Replace. 

FUELSENDERUNITTEST 

1. Remove: 
•Seat 
•Top cover 

2. Measure: 

• Fuel sender unit resistance 
Out of specification-*- Replace. 



□ 



(T) Green 



Fuel Sender Unit Resistance: 
0.9±0.2Kn at20°C (68°F) 

(2) Black 



7-58 



V^OOST SYSTEM 



V^OOST SYSTEM 
CIRCUIT DIGRAM 



HAV 



T 



T 



I 



@ 



R/B @> R/W 



fi/W 

6 I© 



# 



ON 



OFF 



Br 



OOO 



OH fo 



Br 



I I 

B/Y L/Y 

® 



© 



B/Y Sb L/Y 



B 



— R/W^R/W- 



e/w- 



© 



-B/R- 
-B/Y- 



@ 



a 



t — r 

B B 



Gy- 

-Y- 

I — w-; 



7S5 



r~- 



R/W 



O Gy W/R W ji G 

u trb (J 



J- R/G j— R/W- 



-Br- 



i 



M>® ,. 



@ 



t ezri 






-Br- 



-Sb- 
-B/Y- 
-R/B- 
-Gy- 

-L — 



-Br- 



Br Br 



© 



©S^ G Br 



-B- 



® 



1® 



© 



1 



B/Y 



b^^zE^y 




.►fir 



® @i 

Br-0-G/R-^^-^ 
~(V) B — -t_ 

Br — (OV— P — 

— G r=n 



® 



© 



CD 



o-Br-^ ?}^ I (^ y^ 



<-Br— frn) — VAr|-0 O^ 

L/W -— |#J ®> * 

,KBr-@^Sb*-0 0^ 
Sb 1 



I Br Br 



©<£>©<£) 



~> 



7-59 



V-BOOST SYSTEM 



Aforementioned circuit diagram shows V-boost circuit in wiring diagram. 



NOTE: 

For the encircled numbers and color codes, see page 7-2. 



<D 
® 



# 



Ignition coil #2 

Spark plug^#2 

Main fuse 

Battery 

Main switch 

Fuse (IGNITION) 

"ENGINE STOP" switch 

V-boost valve control unit 

Servo motor 

Ignitor unit 

Pick-up coil (#1 ~ #4) 




7-60 



V-BOOST SYSTEM 



V-BOOST SYSTEM 

Description 

The V-Boost consists of a servomotor, a control 
cable, special intake joints and butterfly valves. 
The front and rear cylinders are connected by 
the special intake joint. In the middle of the 
intakejoint is the butterfly valve. 
The butterfly valve is opened and closed by the 
servomotor. And this valve is securely closed 
by means of its return spring. 
The servomotor senses rpm from engine's 
ignition signals and controls the butterfly valve 
operation. The butterfly valve begins to open at 
approximately 6,000 r/min and fully opens at 
approximately 8,000 r/min. 
For example, while the #1 cylinder is in the 
intake stroke, the #2 cylinder is in the com- 
bustion storke and consequently the #2 carb is 
at rest. If the butterfly valve opens in this state, 
an air fuel mixture flows into the #1 cylinder 
through the #1 and #2 carbs (as in the super- 
charger system). 

This results in an increased intake efficiency per 
cylinder, leading to higher performance. 

EJ CYLINDER 

[ COMBUSTION 
[C] EXHAUST 
\D\ INTAKE 
\E\ COMPRESSION 



0° 



180° 



360° 



540° 



720° 



900° 



A 



No. 1 


1 


^« 


IS 


m e 


m 


No. 2 


Dj 


E 


p^« 


® 


No. 3 




«?» 










No. 4 










«» 






180° ± 70"° 



110° 



""> 



"> 



7-61 



V^OOST SYSTEM 



ELEC 



Operation 

TheiE is a lag ii tin e between the starting of the 

servo m otor and the opening of the butterfly 

vaives . This lag is caused by a slack provided 

w ith the control cam e . 

Therefore, the servo m otor starts to operate at 

5,730 engiie r/m in but the val/es beghe to open 

at 6, 000 r/m ±i. 



Battery 
| M ain sw itch 
| Fuse 

|vioostva]ve controluni 
I Potentbm eter 
) D rdve pulley 
| Vacancy 
j Bu tterfly v]ave 

Reduction gear 
j Seivo motor 
j Ijnitor unt 
j Valve angle iifoim atbn 

Motordrive 
I Revolution inform atbn 







7-62 



V-BOOST SYSTEM 



(T) Valve opens 

(5) Valve closed 

(D Servo motor starts 

(4) Main switch "ON" 

(5) 1 second 

(6) Engine starting 

(7) Increased engine speed 
(D Time 

(9) Initial operation 



® 




8,000 rlmin 




(D 



"^ 



^ 



7-63 



V-BOOST SYSTEM 



ELECI 



TROUBLESHOOTING 

Troubleshooting Chart (1) 



When the main switch is turned on, the 
butterfly valves operate one cycle. 



NO 



Check the battery voltage { 1 ~ 1 6 V). 



& 



OK 



When the main switch is turned on after 
the control cable is disconnected, the 
servo motor operate one cycle. 



OK 

■=> 

NO 

■►I 

OK 



Refer to "Troubleshooting Chart (2)" 
section. 



Recharge the battery. 



Check butterfly valves and control cable 
for mechanical faults. Correct any. 



NO 



Check each couplers, lead connections 
and fuse. 



NO 



Correct. 



& 



OK 



Poor condition 



Check for the servo motor condition. 



& 



4 



Replacethe servo motor. 



OK 



Replacethe V-boost valve control unit. 



7-64 



ELEC 



V^OOST SYSTEM 



Troubleshooting Chart (2) 



When the main switch is turned on, the 
butterfly valves operate one cycle. 



4> 



OK 



When the engine speed are increased to 
6,000 r/mjn, the valves are opened. 



* 



NO 

4 

OK 



Refer to "Troubleshooting Chart (1)" 
section. 



Good. 



NO 



Check connection between the ignitor 

ton±and the v^ooost valve control unit. 



$> 



NO 



Correct. 



OK 



Poor condition 



Check No. 2 cylinder for sparks. 



4> 



4C 



Check the ignitor and the ignition coil. 



OK 



Replace the V -boost valve control unit. 



~> 



7-65 







SERVO MOTOR TEST 

1. Disconnect: 

•Servo motor coupler (3) 

2. Connect: 

• Battery (12V) (4) 

3. Check: 

•Servo motor operation 
Not operation-* Replace. 



(J) Black/Red 
(§) Black/Yellow 

4. Measure: 

.Potentiometer resistance 
Use the Pocket Tester (YU-03112). 

Out of specification -* Replace. 



E3 



Potentiometer Resistance: 

7.5 Kfi ± 30% at 20°C (68°F) 
®-©.(©-(D) + (®-®) 



(j) Yellow/Blue 
(|) White/Red 
(D White/Black 



7-66 



CHAPTER 8. 
APPENDICES 



APPX 



IS 



SPECIFICATIONS 

GENERAL SPECIFICATIONS 

MAIWTENANCE SPECI FICATIONS 



8-1 
8-1 
8-3 



GENERAL TORQUE SPECIFICATIONS 



8-18 



DEFINITION OF UNITS 



8-18 



CONVERSION TABLES. 



8-19 



LUBRICATION DIAGRAMS 



8-20 



CABLE ROUTING 



8-24 



CONSUMER INFORMATION 



8-32 



WIRING DIAGRAM 



8-33 



APPX 



IN 



SPECIFICATIONS 



APPENDICES 



SPECIFICATIONS 

GENERAL SPECIFICATIONS 



Model 



VMX12N/NC 



Model Code Number 
Engine Starting Number 
Vehicle Identification Number 



1FK VMX12NC: 

1FK-000101 VMX12NC: 

JYA1FK00*FA000101 
VMX12NC: JYA1 JH00#FA000101 



1JH 
UH-000101 






Dimensions: 
Overall Length 
Overall Width 
Overall Height 
Seat Height 
Wheel base 
Minimum Ground Clearance 



2,300 mm (90.6 in) 
795 mm (31.3 in) 

1,160 mm (45.7 in) 
765 mm (30.1 in) 

1,590 mm (62.6 in) 
145 mm ( 5.7 in) 



~> 



Basic Weight: 
Weight Oil and Full Fuel Tank 



274 kg (604 lb) 
VMX12NC: 275 kg (606 lb) 



Minimum Turning Radius: 



Engine: 
Engine Type 
Cy linder Arrangement 
Displacement 
Bore x Stroke 
Compression Ratio 
Compression Pressure 
Starting System 



2,790 mm (110 in) 



Liquid cooled 4-stroke gasoline, DOHC 

V-4 cylinder 

1,198 cm 3 

76 x 66 mm (2.992 x 2.598 in) 

10.5 : 1 

1,422 kPa (14.5 kg/cm 2 ,206 psi) 

Electric starter 



^ 



Lubrication System: 



Wep sump 



Oil Type or Grade: 
Engine Oil 

30 40 



50 60°F 



10 15°C 



Final Gear Oil 



Yamalube 4-cycle oil or SAE 20W40 type SE 
motor oil (If temperature does not go below 
5°C (40°F)) 

SAE 10W30 type SE motor oil (If temperature 
does not go above 15°C (60°F)) 

SAE 80 API "GL-4" Hypoid gear oil 



^ 



Oil Capacity: 
Engine Oil : 

Periodic Oil Change 

With Oil Filter Replacement 

Total Amount 
Final Gear Case: 

Total Amount 



3.5 L (3.1 Impqt, 3.7 USqt) 
3.8 L (3.3 Impqt, 4.0 USqt) 
4.7 L (4.1 Impqt, 5.0 USqt) 

0.2 L (0.18 Impqt, 0.21 USqt) 



"^ 



Radiator Capacity: 
(Including All routes) 



3.05 L (2.69 Impqt, 3.22 USqt) 



Air Filter: 



Dry type element 



"> 



Fuel: 
Type 

Tank Capacity: 
Total 
Reserve 



Regular gasoline 

15.0 L (3.3 Imp gal, 4.0 US gal) 
3.0 L (0.66 Imp gal, 0.80 US gal) 



8-1 





SPECIFICATIONS 


APPX 


1\ 


J 




Model 


VMX12N/NC 


Carburetor: 
Type/Manufacturer 


BDS34x4/MIKUNI 


Spark Plug: 
Type/Manufacturer 
Gap 


DPR8EA-9/NGK,X24EPR-U9/NIPPONDENSO 
0.8 ~ 0.9 mm (0.031 ~ 0.035 in) 


Clutch Type: 


Wet, multiple-disc 


Transmission: 
Primary Reduction System 
Primary Reduction Ratio 
Secondary Reduction System 
Secondary Reduction Ratio 
Transmission Type 
Operation 
Gear Ratio: 

1st 

2nd 

3rd 

4th 

5th 


Spar gear 
87/49 (1.775) 
Shaft drive 
21/27x33/9 (2.851) 
Constant mesh, 5-speed 
Left foot operation 

43/17 (2.529) 
39/22 (1.772) 
31/23 (1.347) 
28/26(1.076) 
26/28 (0.928) 


Chassis: 
Frame Type 
Caster Angle 
Trail 


Double cradle 

29° 

119 mm (4.7 in) 


Tire: 
Type 

Size(F) 
Size<R) 
Wear Limit 


Tube! ess 

110/90V18 

BRIDGESTONEM120/DUNLOPF17 

150/90V15 

BRIDGESTONE M335/DUNLOP MC720 

1.0 mm (0.04 in) 


Tire Pressure (Cold Tire): 
Basic Weight: 

With Oil and Full Fuel Tank 
Maximum Load* 

Cold Tire Pressure: 
Upto90kg(198lb) Load* 

90 kg (1981b)* ~ 225 kg (496 ib) Load* 

Highspeed Riding 


274kg(604lb) VMX12NC: 275kg (606lb) 
225 kg (496 Ib) 


FRONT 


REAR 


235 kPa 
(2.4 kg/cm 2 , 34 psi) 


255 kPa 
(2.6kg/cm 2 ,36psi) 


235 kPa 
(2.4 kg/cm 2 , 34 psi) 


275 kPa 
(2.8 kg/cm 2 ,40 psi) 


235 kPa 

(2.4 kg/cm 2 ,34 psi) 


255 kPa 
(2.6 kg/cm 2 , 36 psi) 


* Load is the total weight of cargo, rider, 
passenger, and accessories. 


Brake: 
Front 
Operation 
Rear 
Operation 


Dual disc brake 
Right hand operation 
Single disc brake 
Rightfoot operation 


Suspension: 
Front Suspension 
Rear Suspension 


Telescopic fork 
Swing arm 



8-2 







Model 


VMX12N/NC 


Shock Absorber: 




Front Shock Absorber 


Air/Coil spring, Oil damper 


Rear Shock Absorber 


Coil spring, Oil damper 


Wheel Travel: 




Front Wheel Travel 


140 mm (5.5 in) 


Rear Wheel Travel 


100 mm (3.9 in) 


Electrical: 




Ignition System 


T.C.I. 


Generator System 


A.C. magneto generator 


Battery Type or Model 


YB16AL-A2 


Battery Capacity 


12V 16AH 


Headlight Type: 


Bulbtype (Quartz bulb) 


Bulb Wattage x Quantity: 




Headlight 


12V,60W/55Wx 1 


Tail/Brake Light 


12V,8W/27Wx2 


Flasher Light 


12V,27Wx4 


Parking/ Running Light 


12V,8Wx2 


Indicator Light: 




"NEUTRAL" 


12V, 3wx 1 


"HIGH BEAM" 


12V, 3wx 1 


"01 L LEVEL" 


12V,37Vx 1 


"TURN" 


12V, 3wx 1 


"FUEL" 


12V, 3wx 1 


Meter Light 


12V, 3wx4 



MAINTENANCE SPECIFICATIONS 

Engine 



Model 


VMX12N/NC 


Cylinder Head: 
Warp Limit* 


~ L* 




0.03 mm (0.0012 in) 








' 




Cylinder: 
Bore Size 
Taper Limit 
Out of Round Limit 


75.07 - 76.02 mm (2.956- 2.993 in) 
0.05 mm (0.002 in) 
0.05 mm (0.002 in) 


Camshaft: 
Drive Method 
Cam Cap Inside Dia. 
Camshaft Outside Dia. 
Shaft-to-Cap Clearance 
Cam Dimensions 


1 




Chain drive (Center) 

25.000- 25.021 mm (0.9843 " 0.9851 in) 
24.967- 24.980 mm (0.9830- 0.9835 in) 
0.020- 0.054 mm (0.0008- 0.0021 in) 

36.25- 36.35 mm (1.427- 1.431 in) 

36.15 mm (1.423 in) 

28.02- 28.12 mm (1.103- 1.107 in) 

27.02 mm {1.064 in) 

36.25- 36.35 mm (1.427 - 1.431 in) 

36.15 mm (1.423 in) 

28.02- 28.12 mm (1.103- 1.107 in) 

27.02 mm (1.064 in) 


Intake "A" 

< Limit> 
Intake "B" 

< Limit> 
Exhaust "A" 

< Limit> 
Exhaust "B" 

< Limit > 




i 


i 
t 


B m 





^ 



"■> 



8-3 



SPECIFICATIONS 



APPX 



1\ 



Model 



VMX12N/NC 



Camshaft Runout Limit 



0.03 mm (0.0012 in) 




Cam Chain: 
Cam Chain Type/No. of Links 
Cam Chain Adjustment Method 



DID219FTS/118 

Automatic 



Valve, Valve Seat, Valve Guide: 
Valve Clearance (Cold): IN. 

EX. 




"A 1 

" A'HeadDia. 
"B" Face Width 
"C" Seat Width 

< Limit> 

"D" Margin Thickness 

< Limit> 
Stem Outside Dia. 

< Limit> 
Guide Inside Dia. 

< Limit> 
Stem-to-Guide Clearance 

< Limit> 

Stem Runout Limit 




IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 




0.1 1-0.15 mm (0.004 - 0.006 in) 
0.26 ~ 0.30 mm (0.010- 0.012 in) 





30.4- 30.6 mm (1.197- 1.205 

24.9- 25.1 mm (0.980- 0.988 

1.6- 3.1 mm (0.063 -0.1 22 in 

1.3- 2.4 mm (0.051 - 0.095 in 

0.9- 1.1 mm (0.035- 0.043 in 

0.9- 1.1 mm (0.035- 0.043 in 

1.4 mm (0.055 in) 

1.4 mm (0.055 in) 

1.1 " 1.5 mm (0.043- 0.059 in 

1.1 - 1.5 mm (0.043- 0.059 in 

0.7 mm (0.028 in) - 

0.7 mm (0.028 in) 

5.475- 5.490 mm (0.2156- 0. 

5.460 - 5.475 mm (0.21 50 - 0. 

5.445 mm (0.214 in) 

5.420 mm (0.213 in) 

5.500- 5.512 mm (0.2165" 0. 

5.500 - 5.512 mm (0.21 65 - 0. 

5.550 mm (0.219 in) 

5.550 mm (0.219 in) 

0.010- 0.037 mm (0.0004- 0. 

0.025- 0.052 mm(0.CD10~ 

0.08 mm (0.0031 in) 

0.10 mm (0.0039 in) 

0.01 mm (0.0004 in) 



in) 

in) 

) 

) 

) 

) 



2161 in) 
2156 in) 



2170 in) 
2170 in) 



0015 in) 
0020 in) 



8-4 



Model 



VMX12N/NC 



Valve Spring: 
Inner Spring: 
Free Length 

< Limit> 

Set Length (Valve Closed) 



IN. 

EX. 

IN. 

EX. 

IN. 

EX. 



Compressed Pressure (Installed) IN. 

EX. 
Tilt Limit* IN. 

EX. 




Direction 

Outer Spring: 
Free Length 

< Limit> 

Set Length (Valve Closed) 



IN. 
EX. 

IN. 

EX. 

IN. 

EX. 

IN. 

EX. 
Compressed Pressure (Installed) IN. 

EX. 

Tilt Limit* IN. 

— 1|— * EX. 




IN. 
EX. 



39.65 mm (1.561 in) 

39.65 mm (1.561 in) 

37.45 mm (1.474 in) 

37.45 mm (1.474 in) 

31.8 mm (1.25 in) 

31.8 mm (1.25 in) 

6.29- 7.39 kg {13.9- 16.3 1b) 

6.29- 7.39 kg (13.9- 16.31b) 

2.571.7 mm (0.067 in) 

2.571.7 mm (0.067 in) 



Left 
Left 

41.10 mm (1.618 in) 

41.10 mm (1.618 in) 
38.90 mm (1.531 in) 
38.90 mm (1.531 in) 
33.8 mm (1.331 in) 
33.8 mm (1.331 in) 
13.3- 15.7 kg (29.3 
13.3" 15.7 kg (29.3 
2.571.8 mm (0.071 in) 
2.571.8 mm (0.071 in) 



34.6 lb) 
34.6 lb) 



Right 
Right 



Piston: 
Piston Clearance 
< Limit> 
Piston Size "D" 
Measuring Point "H" 



z 



/ 


\ 








I 


_ _ _ J^ 


x/ 


" 


- D — 







0.055 - 0.075 mm (0.0022 " 0.0030 in) 
0.15 mm (0.0059 in) 

75.905 ~ 75.955 mm (2.9884- 2.9903 in) 
6.2 mm (0.244 in) 



8-5 



SPECIFICATIONS 



APPX 



IS 



Model 



VMX12N 



Oversize: 



1st 
2nd 



76.25 mm (3.002 in) 
76.50 mm (3.012 in) 



Piston Ring: 
Top Ring: 
Type 

Dimensions (B xT) 
End Gap (Installed) 

< Limit> 

Side Clearance (Installed) 

< Limit> 
2nd Ring: 

Type 

Dimensions (B xT) 
End Gap (Installed) 

< Limit> 
Side Clearance 

< Limit> 
Oil Ring: 

Dimensions (B xT) 
End Gap (Installed) 





I 
• 







u 



n 



—I 



Barrel 

3.1 x 1.0 mm (0.122x0.040 in) 

0.35- 0.50 mm (0.0138- 0.0197 in) 

0.75 mm (0.0295 in) 

0.03 - 0.07 mm (0.0012- 0.0028 in) 

0.12 mm (0.0047 in) 

Taper 

3.1 x 1.2 mm (0.122x0.047 in) 

0.35 - 0.50 mm (0.0138- 0.0197 in) 

0.75 mm (0.0295 in) 

0.02 ~ 0.06 mm (0.0008- 0.0024 in) 

0.12 mm (0.0047 in) 

3.1 x 2.5 mm (0.122 x 0.098 in) 
0.2 - 0.8 mm (0.0080- 0.032 in) 



Connecting Rod: 
Oil Clearance 
Bearing Color Code 



0.021 - 0.045 mm (0.0008" 0.0018 in) 

1 . Blue 2. Black 3. Brown 4. Green 

5. Yellow 6. Pink 



Crankshaft: 



M. 



P=» 



Runout Limit 
Big End Side Clearance 
Journal Oil Clearance 
Bearing Color Code 



'C" 
•D" 



0.03 mm (0.0012 in) 
0.320 ~ 0.924 mm (0.0126- 0.0364 in) 
0.020 - 0.044 mm (0.0008 " 0.0017 in) 
LBlue 2. Black 3. Brown 4. Green 
5. Yellow 6. Pink 7. Red 



Clutch: 
Friction Plate 



Thickness 
Quantity 
Wear Limit 
Thickness 
Quantity 
Warp Limit 
Free Height 
Quantity 
Minimum Height 
Warp Limit 
Push Rod Bending Limit 



Clutch Plate: 



Clutch Spring: 



2.9- 3.1 mm (0.1 14' 

8 pes. 

2.8 mm (0.1 1 in) 

2.2-2.4 mm (0.087- 

7 pes. 

0.2 mm (0.008 in) 

7.0 mm (0.28 in) 

1 pc. 

6.5 mm (0.26 in) 

0.1 mm (0.004 in) 

0.5 mm (0.02 in) 



0.122 in) 



0.095 in) 



Transmission: 
Main Axle Deflection Limit 
Drive Axle Deflection Limit 



0.08 mm (0.0031 in) 
0.08 mm (0.0031 in) 



8-6 



|appx 


• >| SPECIFICATIONS 










Model 


VMX12N/NC 


Shifter: 






Shifter Type 


Guide Bar 




Guide Bar Bending Limit 


0.025 mm (0.001 in) 




Carburetor: 






I.D. Mark 


1FKOO VMX12NC: 


1JHOO 


Main Jet (M.J.) 


#1 &3 : #152.5 #2&4 :#150 




Main Air Jet (M.A.J.) 


<p2.0 




Jet Needle (J.N.) 


5EZ43 




Needle Jet (N.J.) 


Y-0 




PilotJet (P.J.) 


#37.5 




Pilot Air Jet (P.AJ. 1) 


#90 




(P.AJ. 2) 


#170 




Pilot Screw (P.S.) 


Preset 




Pilot Outlet (P.O.) 


0.9 




Bypass (B.P. 1) 


0.8 




(B.P. 2) 


0.8 




(B.P. 3) 


0.9 




Valve Seat Size (V.S.) 


1.5 




Starter Jet (G.S. 1) 


#45 




(G.S.2) 


#0.8 




Fuel Level 


16± 1.0 mm (0.63 ± 0.04 in) 




Engine Idling Speed 


950 ~ 1,050 r/min 




Vacuum Pressureat Idling Speed 


Above 170 mm Hg(6.69inHg) 




Vacuum Synchronous Difference 


Below 20 mm Hg (0.79 in Hg) 




Fuel Pump: 






Type 


Electircal type 




Consumption Amperage (Max.) 


1.0A 




Out-put Pressure 


1 6.2 ~ 20.1 kPa 






(0.165~ 0.205 kg/cm 2 , 2.35 ~ 2.92 psi) 


Lubrication System: 






Oil FilterType 


Paper type 




Oil Pump Type: 


Trochoid type 




Tip Clearance 


0~ 0.12 mm (0" 0.0047 in) 




< Limit> 


0.17 mm (0.0067 in) 




Side Clearance 


0.03 ~ 0.08 mm (0.0012~ 0.0031 in) 




< Limit> 


0.08 mm (0.0031 in) 




Bypass Valve Setting Pressure 


167~ 235 kPa ( 1.7 ~ 2.4 kg/cm 2 , 24 - 


- 34 psi) 


Relief Valve Operating Pressure 


432 ~ 549 kPa (4.4 ~ 5.6 kq/cm 2 , 63 ~ 80 psi) 



8-7 



SPECIFICATIONS 



APPX 



IN 



Model 



VMX12N/NC 



Lubrication Chart: 




Crankcase Tightening Sequence: 
Lower Case 




Upper Case 



* With wasl 




@*'=i/ 






8-8 



APPX 


A\ 


SPECIFICATIONS 








Model 


VMX12N/NC 


Cooling System: 
Radiator Core Size: Width 

Height 
Thickness 
Radiator Cap Opening Pressure 

Reservoir Tank Capacity 

< From Low to Full Level > 
Water Pump: 

Type 

Reduction Ratio 


363.8 rnrn (14.3 in) 

240 mm (9.45 in) 

16 rnrn (0.63 in) 

73.6 ~ 103.0 kPa 

(0.75 ~ 1.05 kg/cm 2 , 10.7" 14.9 psi) 

0.3 L (0.26 Impqt, 0.32 USqt) 

0.2 L (0.18 Impqt, 0.21 USqt) 

Single-suction centrifugal pump 
31/21 (1.476) 


Shaft Drive: 
, Middle Gear Backlash 

< Limit> 

Final Gear Backlash 

< Limit> 

Ring Gear Stopper Clearance 


0.05 ~ 0.12 mm (0.002~ 0.005 in) 

0.3 mm (0.012 in) 

0.1 ~ 0.2 rnrn (0.004 ~ 0.008 in) 

0.3 rnrn (0.012 in) 

0.30- 0.60 mm (0.012- 0.024 in) 



~> 



8-9 



SPECIFICATIONS 



APPX 



IN 



TIGHTENING TORQUE 



Part to be Tightened 


Part Name 


Thread Size 


Q'ty 


Tightening Torque 


Remarks 


*>■ * •. w —r^r ■ »j. 1..W1 ■ «« 






Nm 


m-kg 


fflb 


Camshaft Cap 


Bolt 


M6 x 1.0 


32 


10 


1.0 


7.2 




Spark Plug 


— 


M12x 1.25 


4 


17.5 


1.75 


12.5 




Cylinder Head 


Nut 


M10x 1.25 


16 


43 


4.3 


31 




Cylinder Head Cover 


Bolt 


M6 x 1.0 


16 


10 


1.0 


7.2 




Connecting Rod 


Bolt 


M8 x0.75 


8 


36 


3.6 


25 


-g.* 


AC MagnetoRotor 


Bolt 


M12x 1.25 


1 


130 


13.0 


94 




Cam Sprocket 


Flange bolt 


M7 x 1 .0 


8 


24 


2.4 


17 




Plate (Damperchain) 


Flange bolt 


M8 x 1.25 


1 


24 


2.4 


17 


— <a 


Tensioner 


Bolt 


M6 x 1.0 


4 


12 


1.2 


8.7 




Tensioner Stopper Bolt 


Bolt 


M16x 1.0 


2 


20 


2.0 


14 




Water Pump Cover 


Bolt 


M6 x 1.0 


6 


10 


1.0 


7.2 




Water Pump Housing 


Bolt 


M6 x 1.0 


3 


10 


1.0 


7.2 




Coolant Drain Plug 


Bolt 


M14x 1.5 


1 


43 


4.3 


31 




Thermostatic Valve Housing 


Bolt 


M6 x 1.0 


2 


10 


1.0 


7.2 




Thermostatic Valve Cover 


Screw 


M6 x 1.0 


2 


7 


0.7 


5.1 




Electric Fan Motor 


Screw with 
washer 


M5 xO.8 


3 


4 


0.4 


2.9 




Electric Fan 


Nut 


M5 x0.8 


1 


4 


0.4 


2.9 




Radiator Assembly 


Boltwith 
washer 


M6 x 1.0 


4 


7 


0.7 


5.1 




Breather Cover 


Bolt 


M6 x 1.0 


10 


10 


1.0 


7.2 




Radiator Cover 


Screw 


M5 x0.8 


4 


4 


0.4 


2.9 




Cover (Left and right) 


Screw 


M5 x0.8 


4 


4 


0.4 


2.9 




Conduit 


Screw 


M6 x 1.0 


6 


7 


0.7 


5.1 




Oil Pump Cover 


Screw 


M6 x 1.0 


6 


7 


0.7 


5.1 




Oil Strainer Housing 


Screw 


M6 x 1.0 


3 


7 


0.7 


5.1 




Oil Pump 


Bolt 


M6 x 1.0 


3 


10 


1.0 


7.2 




Oil Filter Cover 


Union bolt 


M20x 1.5 


1 


32 


3.2 


23 




Engine Oil Drain Bolt 


Bolt 


M14x 1.5 


1 


43 


4.3 


31 




Oil Pan 


Bolt 


M6 x 1.0 


12 


10 


1.0 


7.2 




Oil Baffle Plate 


Flange bolt 


M6 x 1.0 


2 


12 


1.2 


8.7 




Oil Delivery Pipe (Lower) 


Union bolt 


M8 x 1.25 


2 


18 


1.8 


13 




Oil Delivery Pipe (Upper) 


Union bolt 


M10x 1.25 


1 


20 


2.0 


14 




Oil Delivery Pipe (4) 


Flange bolt 


M6 x 1.0 


2 


12 


1.2 


8.7 




Oil Pipe 


Union bolt 


M8 x 1.25 


1 


18 


1.8 


13 




Stay 1 


Flange bolt 


M6 x 1.0 


1 


12 


1.2 


8.7 




Carburator Joint 


Bolt 


M6 x 1.0 


8 


10 


1.0 


7.2 




Fuel Pump 


Flange bolt 


M6 x 1.0 


2 


12 


1.2 


8.7 




Wire Pulley 


Screw 


M5 x 0.8 


1 


4 


0.4 


2.9 




Valve Cover 


Screw 


M6 x 1.0 


4 


7 


0.7 


5.1 




Wire 


Screw 


M5 x 0.8 


2 


4 


0.4 


2.9 




Exhause Pipe(# 1, #3) &Joint 


Bolt 


M6 x 1.0 


2 


7 


0.7 


5.1 




Exhaust Pipe Connection 


Bolt 


M8 x 1.25 


1 


20 


2.0 


14 




Exhaust Pipe Flange 


Nut 
Bolt 


M8 x 1.25 
M5 x 0.8 


8 
6 


20 
7 


2.0 
0.7 


14 
5.1 




Exhaust Cover 


Screw 


M5 x 0.8 


4 


4 


0.4 


2.9 




Muffler Stay 


Bolt 


M6 x 1.0 


2 


10 


1.0 


7.2 




Muffler 


Bolt 


M10x 1.25 


3 


25 


2.5 


18 




Exhaust and Chamber 


Bolt 


M8 x 1.25 


4 


20 


2.0 


14 





8-10 



APPX 


IN 


SPECIFICATIONS 


























Part to be Tightened 


Part Name 


Thread Size 


Q'ty 


Tightening Torque 


Remarks 


O ■**•*■ "ww 






Nm 


m-kg 


ft- lb 




Crankcase 


Bolt 


M6 x 1.0 


10 


12 


1.2 


8.7 




Crankcase 


Bolt 


M8 x 1.25 


19 


24 


2.4 


17 




Crankcase 


Bolt 


M10x 1.25 


8 


40 


4.0 


29 




Dive Axle Bearing Retainer 


Torx screw 


M8 x 1.25 


4 


25 


2.5 


18 


Stake 


Main Axle Bearing Retainer 


Screw 


M6 x 1.0 


3 


7 


0.7 


5.1 


-o 


Crankcase Cover (Left) 


Bolt 


M6 x 1.0 


11 


10 


1.0 


7.2 




Lead Clamp 


Screw 


M6 x 1.0 


2 


7 


0.7 


5.1 




Crankcase Cover (Right) 


Bolt 


M6 x 1.0 


6 


10 


1.0 


7.2 




Middle Gear Case Cover 


Bolt 


M6 x 1.0 


9 


10 


1.0 


7.2 




Middle Gear Oil Drain Bolt 


Bolt 


M8 x 1.25 


1 


38 


3.8 


27 




Startor One-way Clutch 


Bolt 


M8 x 1.25 


3 


24 


2.4 


17 


-o 


Clutch Boss 


Nut 


M20x 1.0 


1 


70 


7.0 


50 


Use lock washer 


Clutch Release Cylinder 


Special 


M6 x 1.0 


2 


12 


1.2 


8.7 




Clutch Pressure Plate 


Bolt 


M6 x 1.0 


6 


8 


0.8 


5.8 




Middle Drive Gear 


Nut 


M44x 1.5 


1 


110 


11 


80 


Stake 


Middle Drive Shaft 


Self-lock nut 


M14x 1.5 


1 


90 


9.0 


65 


— <3 


Middle Drive Shaft Bearing Housing 


Bolt 


M8 x 1.25 


3 


30 


3.0 


22 




Shift Cam Segment 


Screw 


M6 x 1.0 


1 


12 


1.2 


8.7 


-<a 


Shift Cam Plate (Neutral) 


Screw 


M5 x0.8 


1 


4 


0.4 


2.9 


— Gj 


Shift Cam Bearing Stopper 


Screw 


M6 x 1.0 


3 


7 


0.7 


5.1 


-3a 


Change Lever Adjuster 


Screw 


M8 x 1.25 


1 


22 


2.2 


16 


Use lock washer 


Shift Cam Stopper Lever 


Screw with 
washer 


Mfi x 1 .0 


1 


8 


0.8 


5.8 


— O 


Change Pedal Adjuster Lock 


Nut 


M6 x 1.0 


4 


10 


1.0 


7.2 




Change Pedal/Linkage Pinch Bolt 


Bolt 


M6 x 1.0 


3 


10 


1.0 


7.2 




Thermostatic Switch 


__ 





1 


15 


1.5 


11 


Apply Sealant 


Thermo-unit 


__ 


_ 


1 


15 


1.5 


11 


Apply Sealant 


Neutral Switch 


Screw 


M5 x 0.8 


3 


4 


0.4 


2.9 




Starter Motor 


Flange bolt 


M6 x 1.0 


2 


10 


1.0 


7.2 




Oil Level Switch 


Boltwith 
washer 


MG x1.0 


2 


10 


1.0 


7.2 




ACM Stator 


Screw 


M6 x 1 .0 


3 


7 


0.7 


5.1 




Pick-up Coil 


Screw 


M6 x 1.0 


4 


7 


0.7 


5.1 




Bearing Housing 


Nut 
Flange bolt 


M8 x 1.25 
M10x 1.25 


6 
2 


23 

40 


2.3 

4.0 


17 
29 




Bearing Retainer 


Retainer 


M65x 1.5 


1 


110 


11.0 


80 




Coupleinggear 


Nut 


M14x 1.5 


1 


110 


11.0 


80 


^ca 


Final Gear Filler Bolt 


Bolt 


M14x 1.5 


1 


23 


2.3 


17 




Fianl Gear Drain Bolt 


Bolt 


M14x 1.5 


1 


23 


2.3 


17 





8-11 



SPECIFICATIONS 




Chassis 



Model 


VMX12N/NC 


Steering System: 






Steering Bearing Type 




Taper roller bearing 


Front Suspension: 






Front Fork Travel 




140 mm (5.51 in) 


Fork Spring Free Length 




492.5 mm (19.4 in) 


< Limit> 




487.5 mm (19.2 in) 


Collar Length 




136 mm (5.35 in) 


Spring Rate: 


K1 


3.92 N/mm (0.4 kg/mm, 22.4 lb/in) 




K2 


4.90 N/mm (0.5 kg/mm, 28.0 lb/in) 


Stroke: 


K1 


0- 78mm{0" 3.07 in) 




K2 


78~ 140mm (3.07 - 5.51 in) 


Optional Spring 




No. 


Oil Capacity 




451 cm 3 (15.9 Impoz, 15.3 US oz) 


Oil Level 




139mm (5.5 in) 


Oil Grade 




Yamaha fork oil 10wt or equivalent 


Enclosed Air Pressure (Standard) 


39.2 kPa (0.4 kg/dm 2 , 5.7 psi) 


< Min. ~ Max. > 




39.2 ~ 98.1 kPa 

(0.4 ~ 1.0 kg/cm 2 , 5.7 ~ 14.2 psi) 


Rear Suspension: 






Shock Absorber 1 Travel 




85 mm (3.35 in) 


Spring Free Length 




245.5 mm (9.67 in) 


< Limit> 




240.5 mm (9.47 in) 


Fitting Length 




217.5 mm (8.56 in) 


Spring Rate: 


K1 


19.1 N/mm (1.95 kg/mm, 109lb/in) 




K2 


26.5 N/mm (2.7 kg/mm, 151 lb/in) 


Stroke: 


K1 


0~ 50 mm (0~ 1.97 in) 




K2 


56- 85 mm (1.97- 3.35 in) 


Optional Spring 




No. 


Rear Arm: 






Swingarm Free Play Limit: 


End 


Zero mm (Zero in) 




Side 


Zero mm (Zero in) 


Front Wheel: 






Type 




Cast wheel 


Rim Size 




MT2.15x 18 


Rim Material 




Aluminum 


Rim Runout Limit: 


Vertical 


2 mm (0.08 in) 




Lateral 


2 mm (0.08 in) 


Rear Wheel: 






Type 




Cast wheel 


Rim Size 




MT3.50 x 1 5 


Rim Material 




Aluminum 


Rim Runout Limit: 


Vertical 


2 mm (0.08 in) 




Lateral 


2 mm (0.08 in) 


Front Disc Brake: 






Type 




Dual 


Disc Outside Diameter x Thickness 


282x7.5 mm (11.1 x 0.30 in) 


Pad Thickness 


Inner 


5.5 mm (0.22 in) 


< Limit>* 




0.5 mm (0.02 in) 


Pad Thickness 


Outer 


5.5 mm (0.22 in) 


< Limit>* 


* 


0.5 mm (0.02 in) 


f.v--vr:A-.:j 


r l ; 



8-12 



APPX 


IN 


SPECIFICATIONS 












Model 


VMX12N/NC 


Master Cylinder Inside Diameter 
Caliper Cylinder Inside Diameter 
Brake Fluid Type 


15.87 mm (0.63 in) 
45.4 mm (1.79 in) 

DOT #3 


Rear Disc Brake: 
Type 

Disc Outside Diameter x Thickr 
Pad Thickness 

< Limit>* 
Pad Thickness 

< Limit>* 

i 


less 
Inner 

Outer 

f 
* 


Single 

282x7.5 mm (11.1 x 0.30 in) 

5.5 mm (0.22 in) 

0.5 mm (0.02 in) 

5.5 mm (0.22 in) 

0.5 mm (0.02 in) 

12.7 mm (0.50 in) 
42.85 mm (1.69 in) 
DOT #3 




l:::.:-v::::^:.vi 




1 


er 
ter 


Master Cylinder Inside Diamet 
Caliper Cylinder Inside Diame 
Brake Fluid Type 


Clutch: 
Master Cylinder Inside Diameter 
Release Cylinder Inside Diameter 
Brake Fluid Type 


15.87 mm (0.63 in) 
38.1 mm (1.50 in) 

DOT #3 


Brake Lever and Brake Pedal: 
Brake Lever Free Play 
Brake Pedal Position 
Brake Pedal Free Play 


2" 5 mm (0.08 ~ 0.20 in) 
20 mm (0.8 in) 
Adjustment not permitted 



Front Fork 


Rear Shock Absorber 


Loading Condition 


Air pressure 


Spring 

seat 


Damping 
adjuster 


Solo 
rider 


With 
passenger 


With accessory 
equipments 


With accessory 

equipments 
ana passenger 


39.2 ~ 58.8 kPa 

(0.4 ~ 0.6 kg/cm 2 , 

5.7 ~ 8.5 psi) 


1or2 


1 or2 


O 








39.2 - 98.1 kPa 

(0.4- 1.0 kg/cm 2 , 

5.7 ~ 14.2 psi) 


3~ 5 


2- 4 




O 


O 




39.2 - 98.1 kPa 

(0.4 ~ 1.0 kg/cm 2 , 

5.7 ~ 14.2 psi) 


5 


4 








O 



"> 



~\ 



8-13 



SPECIFICATIONS 



APPX|1<\| 



TIGHTENING TORQUE: 



Part to be Tightened 


Thread Size 


Tight 


ening Torque 


Remarks 


Nm 


nvkg 


ft- lb 


Front Wheel Axle 


M14x 1.5 


60 


6.0 


43 




Front Axle Pinch Bolt 


M8 x 1.25 


20 


2.0 


14 




Under Bracket & Inner Tube 


M8 x 1.25 


23 


2.3 


17 




Steering Crown & Inner Tube 


M8 x 1.25 


20 


2.0 


14 




Steering Crown & Steering Shaft 


M22x 1.0 


110 


11.0 


80 




Steering Shaft Ring Nut (Lower) 
Steering Shaft Ring Nut (Lower) 


M25x 1.0 
M25x 1.0 


50 
3 


5.0 
0.3 


36 
2.2 


Refer to 
NOTE. 


Steering Shaft Ring Nut (Upper) 


M25x 1.0 


- 


— 


- 




Caliper & Front Fork 


MlOx 1.25 


45 


4.5 


32 


Front 


Caliper & Bracket 


M10x 1.25 


45 


4.5 


32 


Rear 


Caliper & Bleed Screw 


M8 x 1.25 


5 


0.5 


3.6 




Brake Hose Union Bolt 


Ml Ox 1.25 


25 


2.5 


18 




Clutch Hose Union Bolt 


MlOx 1.25 


25 


2.5 


18 




Brake Hose & Brake Pipe 


MlOx 1.0 


19 


1.9 


13 




Clutch Hose& Clutch Pipe 


M10x 1.0 


19 


1.9 


13 




Front Master Cylinder Cap 


M4 x 0.7 


1 


0.1 


0.7 


Brake & Clutch 


Front Brake Master Cylinder Bracket 


M6 x 1.25 


9 


0.9 


6.5 




Clutch Master Cylinder Bracket 


M6 x 1 .25 


9 


0.9 


6.5 




Rear Master Cylinder Union Bolt 


MlOx 1.25 


25 


2.5 


18 




Rear Master Cylinder & Frame 


M8 x 1.25 


23 


2.3 


17 




Pivot Shaft (Left)& Frame 


M22x 1.5 


100 


10.0 


72 




Pivot Shaft (Right) & Frame 


M25x 1.5 


6 


0.6 


4.3 




Pivot Shaft (Right)& Locknut 


M25x 1.5 


100 


10.8 


72 




Front Fender & Fork Brace 


M6 x 1.0 


9 


0.9 


6.5 




Handlebar Upper Holder 


M8 x 1.25 


20 


2.0 


14 




Handlebar Lower Holder 


MlOx 1.25 


40 


4.0 


29 




Engine Bracket (Front upper) 


MlOx 1.25 


40 


4.0 


29 




Engine Bracket (Front Lower) 


MlOx 1.25 


40 


4.0 


29 




Engine Bracket (Rear) 


M12x 1.25 


70 


7.0 


50 




Engine Stay & Frame 


M8 x 1.25 


15 


1.5 


11 




Down Tube & Frame 


MlOx 1.25 


45 


4.5 


32 




Frame and Front Cross Frame 


M8 x 1.25 


20 


2.0 


14 




Muffler Bracket ( Left) & Frame 


M8 x 1 .25 


25 


2.5 


18 




Muffler Bracket (Left)& Backstay 


M8 x 1.25 


25 


2.5 


18 




Back Stay & Frame 


M8 x 1.25 


30 


3.0 


22 




Rear Shock Absorber & Frame 


M8 x 1.25 


20 


2.0 


14 




Rear Shock Absorber & Swingarm 


MlOx 1.25 


30 


3.0 


22 




Rear Shock Absorber & Housing Gear 


MlOx 1.25 


30 


3.0 


22 




Swingarm & Housing Gear 


MlOx 1.25 


42 


4.2 


30 




Rear Wheel Axle & Nut 


M18x 1.5 


120 


12.0 


85 




Footrest Bracket (Left) & Frame 


MlOx 1.25 


40 


4.0 


29 




Footrest Bracket (Right) & Frame 


M8 x 1.25 


23 


2.3 


17 





NOTE: 



8-14 



APPX 



i\ 



SPECIFICATIONS 



Electrical 



Model 



Voltage: 



Ignition System: 
Ignition Tinning (B.T.D.C.) 
Advanced Tinning (B.T.D.C.) 
Advancer Type 



VMX12N/NC 






12v 



3" at 1,000 r/min 
43" at 9,000 r/min 
Vacuum and electrical 



60 

en 

C 

as 

-5 40 

•- si 

^ 20 





































— 
























































,10.6 kPa (80mmHg, 3.15 in 


HgJ 


































































































































V 5.3 kPa (40 mmHg, 


1.57 


inHg) 















































4 5 6 7 8 9 



T.C.I.: 
Pickup Coil Resistance (Color) 

T.C.I. Unit-Model/Manufacturer 



Ignition Coil: 
Model/Manufacturer 
Primary Winding Resistance 
Secondary Winding Resistance 



Charging System/Type: 



AC Generator: 
Model/Manufacturer 
Nominal Output 



110O+ 15%at20°C (68°F) 

(Orange— Black), (Orange— Gray) 

(Orange - White/Green), (Orange - White/Red) 

TID14-43/HITACHI 



CM11-61/HITACHI 
2.7f2+ 10%at20°C (68°F) 
13.2 kn + 20%at20°C(68°F) 



AC magneto generator 



FL130-04/HITACHI 

14V, 25A at 5,000 r/min 



i 



3 
O 



30 



20 



£ 10 

o 




~> 



~> 



2 3 4 5 

Engine speed (x 10 3 r/min) 



^ 



8-15 





SPECIFICATIONS 


APPX 


i\ 






Model 


VMX12N/NC 


Voltage Regulator: 
Type 

Model/Manufacture 
No Load Regulated Voltage 


Short control 
SH569/SHINDENGEN 
14- 15V 


Rectifier: 

Model/Manufacturer 
Capacity 
Withstand Voltage 


SH569/SHINDENGEN 

25A 

200v 


Battery: 
Capacity 
Specific Gravity 


12V, 16AH 
1.280 


Electric Starter System: 
Type 
Starter Motor: 

Model/Manufacturer 

out put 
Bush: 

Overall Length 

< Limit> 
Spring Pressure 

Commutator: 
Outside Diameter 

< Wear Limit > 
Mica Undercut 

Starter Relay: 
Model/Manufacturer 
Amperage Rating 
Coil Winding Resistance 


Constant mesh type 

SM-229C/MITSUBA 
0.6 kW 

12.5 mm (0.49 in) 

5.5 mm (0.22 in) 

560- 680 g (19.7- 23.9 oz) 

28 mm (1.1 in) 
27 mm (1.06 in) 
0.7 mm (0.028 in) 

A104-128/HITACHI 

1COA 

3.552 ± 10%at20°C (68"F) 


Horn: 

Type/Quantity 
Model/Manufacturer 
Maximum Amperage 


Plain type x 1 

CF-12/NIKKO 

2.5A 


Flasher Relay: 
Type 

Model/Manufacturer 
Self Cancelling Device 
Flasher Frequency 
Wattage 


Semi transister type 

FX257N/N IPPONDENSO 

Yes. 

75— 95 cycle/min 

27Wx2+3.4W 


Self Cancelling Unit: 
Model/Manufacturer 


FX257N/NI PPONDENSO 


Oil Level Switch: 
Model/Manufacturer 


1FK/N IPPONDENSO 


Fuel Gauge: 
Model/Manufacturer 
Sender Unit Resistance (Full) 


1FK/NIPP0NSEIKI 
900±200n at20°C (68"F) 


Sidestand Relay: 

Model/Manufacturer 
Coil Winding Resistance 
Diode 


4U8-00/OM RON 

10052 ± 10%at20 9 C (68°F) 
No. 



8-16 



APPX 


IN 


SPECIFICATIONS 








Model 


VMX12N/NC 


Starting Circuit Cut-off Relay: 
Model/Manufacturer 
Coil Winding Resistance 
Diode 


G4MW-1121T-100-Y10/TATEISHI 
225n ± 10%at20°C (68"F) 
Yes. 


Fuel Pump Relay: 
Model/Manufacturer 
Coil Winding Resistance 


G8D-04Y/OM RON 

10012 ± 10%at20"C(68°F) 


Electric Fan: 
Model/Manufacturer 


26H/NIPPONDENSO 


Thermostatic Switch: 
Model/Manufacturer 


47X/N IPPON THE RMOSTAT 


Thermo-unit: 
Model/Manufacturer 


11M/NIPPONSEIKI 


Circuit Breaker: 

Type 

Amperage for Individual Circuit x Quantity 

Main 

Headlight 
Signal 
Ignition 
Reserve 


Fuse 

30Ax 1 
15Ax 1 

, 10Ax 1 
10Ax 1 
30Ax 1 

' 15Ax 1 
10Ax 1 



~> 



8-17 



GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITS 



GENERAL TORQUE SPECIFICATIONS 

This chart specifies torque for standard fasteners 
with standard I.S.O. pitch threads. Torque 
specifications for special components or assem- 
blies are included in the applicable sections of 
this book. To avoid warpage, tighten multi- 
fastener assemblies in a crisscross fashion, in 
progressive stages, until full torque is reached. 
Unless otherwise specified, torque specifications 
call for clean, dry threads. Components should 
be at room temperature. 




A 
(Nut) 


B 

(Bolt) 


General torque 
specifications 


Nm nvkg | fflb 


10 mm 


6 mm 


6 


0.6 


4.3 


12 mm 


8 mm 


15 


1.5 


11 


14mm 


10 mm 


30 


3.0 


22 


1 7mm 


,12 mm 


55 


5.5 


40 


19 mm 


14mm 


85 


8.5 


61 


22mm 


16mm 


130 


13.0 


94 




Unit 


Read 


Definition 


Measure 


mm 
cm 


millimeter 
centimeter 


10" 3 meter 
10 _i meter 


Length 
Length 


kg 


kilogram 


10 3 gram 


Weight 


N 


Newton 


1 kg x m/sec 2 


Force 


Nm 
m-kg 


Newton meter 
Meter kilogram 


N x m 
m x kg 


Torque 
Torque 


Pa 
N/mm 


Paskal 

Newton per millimeter 


N/m 2 
N/mm 


Pressure 
Spring rate 


L 
cm 3 


Liter 

Cubic centimeter 


- 


Volume or Capacity 


r/min 


Rotation per minute 





Engine speed 



8-18 




CONVERSION TABLES 



CONVERSION TABLES 



Metricto inch system 


Known 


Multiplier 


Result 




7.233 


ft- lb 




86.80 


in-lb 


cnvkg 


0.0723 


ft- lb 


cm -kg 


0.86S0 


in-lb 


kg 


2.205 


lb 


g 


0.03527 


oz 


km/lit 


2.352 


mpg 


km/hr 


0.6214 


mph 


km 


0.6214 


mi 


m 


3.281 


ft 


m 


1.094 


yd 


cm 


0.3937 


in 


mm 


0.03937 


in 


cc (cm 3 ) 


0.03382 


02 (USIiq) 


cc (cm 3 ) 


0.06102 


cu in 


lit (Iter) 


2.1134 


pt (USIiq) 


lit (liter) 


1.057 


qt (USIiq) 


lit (liter) 


0.2642 


gal (USIiq) 


kg/mm 


56.007 


lb/in 


kg/cm 2 


14.2234 


psi (lb/in 2 ) 


Centigrade ( C) 


9/5 (°C) + 32 


Fahrenheit (°F) 



In 


3h t o metric system 


Known 


Multiplier 


Result 


ft- lb 


0.13826 


nvkg 


in-lb 


0.01152 


nvkg 


ft- lb 


13.831 


cm -kg 


in-lb 


1.1521 


cm-kb 


lb 


0.4535 


kg 


oz 


28.352 


g 


mpg 


0.4252 


km/lit 


mph 


1.609 


km/hr 


mi 


1.609 


km 


ft 


0.3048 


m 


yd 


0.9141 


m 


in 


2.54 


cm 


in 


25.4 


mm 



oz (USIiq) 


29.57 


cc (cm 3 ) 


cu in 


16.387 


cc (cm 3 ) 


pt (USIiq) 


0.4732 


lit (liter) 


qt (USIiq) 


0.9461 


lit (liter) 


gal (US)iq) 


3.785 


lit (liter) 


lb/in 


0.01 7855 


kg/mm 


psi (lb/in 2 ) 


0.07031 


kg/cm 2 


Fahrenheit ( C) 


5/9 (°F -32) 


Centigrade ( F) 



~> 



8-19 



LUBRICATION DIAGRAMS |APPX ^^V 



LUBRICATION DIAGRAMS 
LUBRICATION DIAGRAM {1) 




8-20 



APPX|1N| 



LUBRICATION DIAGRAMS 



LUBRICATION DIAGRAM (2) 




8-21 



LUBRICATION DIAGRAMS 



APPX 



LUBRICATION DIAGRAM (3) 



IN 




8-22 



APPX 



A\ 



LUBRICATION DIAGRAMS 



LUBRICATION DIAGRAM (4) 





8-23 



CABLE ROUTING 



APPX 



IS 



CABLE ROUTING 

(D Headlight body 

® Hose guide 

(I) Front flasher light lead (Left) 

® Clutch hose 

® Speedometer cable 

© Front brake hose 



@Brake joint 
©Wireharness 
©Speedometer light lead 
@Front flasher light lead (Right) 
CD Front brake hose 




8-24 



APPX 



i\ 



CABLE ROUTING 



© Fuel pump control unit 

(2) Relay unit 

(D V-boost valve control unit 

@V-boost valve control unit lead 

(5) Clamp 

©Clutch hose clamp 

7 Throttle cable joint 

(8) Fuse box 

(9) Band 
(fiSMgnitor unit 
(Q) Ignition coil 



® Sidestand relay 

©Clamp 

@ Radiator fan lead H 

(f|) Horn lead 

©Clamp 

(17) Guide (For speedometer cable) 

(OP Clamp (For brake hose) [q] 

19 Guide (For throttle cable) 

<t§) Guide (For clutch hose) E] 

<££ Handlebarswitch lead (Left) 



Pass the handlebar switch lead 
inside the clutch hose 
Pass the meter lead outside the 
clutch hose. 

Pass the clutch hose outside the 
throttle cable. 

Pass the brake hose outside the 
speedometer cable. 
Pass the clutch hose under the 
throttle cable guide. 




-> 



^ 



8-25 



CABLE ROUTING 



APPX 



IS 



(D Main fuse 

(2) Ignition coil 

(3) Oil level switch lead 
v£) Neutral switch lead 
(5^ Regulater lead 

V&) Sidestand switch lead 

® Rectifier/Regulater lead 
5/ A.C. generator lead 

® Band 

@ Clamp 



(Q) Guide (For clutch hose) 

CljP Clamp (For sidestand switch lead) 

(Q) Clamp 

(H) Clamp (For clutch hose) 

© Starter relay 

Pass the band through the guide on frame 

on frame. 




8-26 



APPX|1SJ 



CABLE ROUTING 



(D Handlebar switch lead 

(D Diode 

(3) Ignitorunit 

© Ignition coil lead 

(5) Conduit lead 

©Band 

©Starter relay 

(D Battery negative (— ) lead 

® Ignition coil 

© ignition coil lead 

(£j) Starter relay lead 

(©Fuel filter 



<0) Boot cover 
©Taillight lead 
<0> Rear flasher light lead (Left) 
©Ignition coil lead 
©Pick up coil lead 
©Starter relay lead 
@Starter motor lead 
©Sidestand switch lead 
© Regulater lead 
@Oil level switch lead 
@ Neutral switch lead 
©Battery positive (+) lead 



<£§) Main fuse 

©Fuel pump 

@ Fuse box 

@ V-boost valve control unit 

@Meter lead 

(Ai Clamp the taillight lead and 

rear flasher light lead (Right). 
JL Clamp the rear flasher light 

lead (Left). 




8-27 



CABLE ROUTING 



APPX 



i\ 



@Earth lead 

©Conduit 

©Handlebar 'switch lead (Left) 

©Ignition coil lead 

©To conduit 

S Earth lead 
Rear brake switch lead 
® Battery breather hose 

fDCoolant reservoir tank breather hose 
9 Fuel sender lead 
Qj) Rear brake switch lead 
©Band 



(j|) Battery negative {—) lead 
@ Coolant reservoirtank 
(g)Band 

@Main switch lead 
(j7)Main switch 
{J|)Rear brake reservoirtank 
©Battery box 

@ Clamp (For battery breather hose) 

©Guide (For reservoirtank breather 

hose and Battery breather hose) 







Pass the wirehamess outside the 
main switch stay. 
Earth lead: 

Pass the earth lead outside the 
reservoirtank breather hose. 
Guide (For battery breather hose, 
reservoirtank breather hose and 
rear brake switch lead). 



n 




8-28 



APPX 



±\ 



CABLE ROUTING 



(T) Fuel filter bracket 
(D Fuel filter 
(3) Fuel pipe 
(£) Filler cover 
® Filler cap 



(6) Battery band 

(7) Fuel pump 

(8) Clamp 
® Fuel pipe 




~> i 



R-9Q 



CABLE ROUTING 



APPX 



±N 



(T) Reservoir tank 

©clip 

(D Spring 

(4) clip 

(D Filler cover 

© Pipe joint 

©clip 

(D Drain hose 

(9) Band 



@ Over flow hose 

(Q)Over flow valve 

@ Clamp 

<Q> Holder 

©Clamp 

(jj) Fuel sender 

(j|) Clamp 

(U Battery breather hose 





8-30 



APPX 



IN 



CABLE ROUTING 



CANISTER PIPE ROUTING 

(T) To carburetor 

(3) To fuel tank 
(D To atmosphere 

(4) Canister 



~> 




~> f 



~> 



^ 



8-31 



CONSUMER INFORMATION 




CONSUMER INFORMATION 



NOTICE 

The information presented represents results obtainable by skilled drivers under controlled road 
and vehicle conditions, and the information may not be correct under other conditions. 



These figures indicate braking performance that can be met or exceeded by the vehicles to which 
they apply, without locking the wheels, under different conditions of loading and with partial 
failures of the braking system. 

The information presented represents results obtainable by skilled drivers under controlled road 
and vehicle conditions and the information may not be correct under other conditions. 


Descriptionof vehicles to which this table applies.: Yamaha motorcycle VMX12N/NC 


A. Fully Operational Service Brake Load 

Light 
Maximum 




168 




^]184 




NOTE: 

The statement above is required by U.S. Federal 
law. "Partial failures" of the braking system do 
not apply to this chart. 


100 200 300 (Feet) 
Stopping distance in feet from 60 mi/h 



8-32 





-H§H 



— &\j>- 




! ■ 



|J) OlTS *' , 

.,(-J . lh J 4J H p j ' .,!_i; 



I— <SH 



"B3=fr 

-«-0=>»— 



±£>H 






_r-©] 



iOl 



iOJ* 



7»~S - 1 - 1 5 A - ~~T* r^Tl 




::::::::::::::::::::::::::::::. o 
a 



» -< -< 

£ a a 
5. f f 



UIivQVDnv 



s-!!JJZ3.3.3.S.cccb 



S e s frs s 3SS 






S = » f a J? 



II 



Z 

o 

S 

z 

Q 

> 

33 
> 



Being a Yamaha owner, you obviously prefer 
a quality product. 



genuine 

ad j 1. Real 2. Authentic, 
not artificial 3. Yamaha. 

GENUINE YAMAHA PARTS & ACCESSORIES 



Don't compromise the quality and 
performance of your Yamaha with off-brand 
alternatives. You'll begetting exactly what 
you're paying for. 



r^ 



n 



-^ 



PROTECT YOUR INVESTMENT 

Use Genuine YAMAHA Parts And Accessories 




n 



YAMAHA MOTOR CORPORATION, U.S.A 
PRINTED IN U.S.A.